Hager's Eureka program drives innovation in plastic extrusion
09.April 2026
Plastic extrusion is a key technology behind modern solutions for electrical installations. Through its global Eureka expert program, Hager connects specialists across sites and generations to continuously improve materials, tooling and processes.
A key technology for electrical applications
Modern buildings, energy systems and charging infrastructures demand components that are lightweight, durable and electrically safe. Plastic extrusion is one of the key technologies that makes this possible.
Through its Eureka program, a global programme that connects and develops technical expertise across sites, Hager ensures that knowledge in this critical technology is continuously shared, refined and anticipated to meet the highest quality standards and evolving market demands.
By melting and shaping specialised polymer materials into precise profiles, manufacturers can produce a wide variety of profiles with very different geometries for diverse applications. These profiles combine electrical insulation, mechanical stability and design flexibility. In many cases, these properties make plastics the material of choice.
But the process is highly sensitive. Material behaviour, tool geometry and machine parameters must be perfectly aligned. Even minor deviations can affect dimensional stability, surface quality or long-term performance, potentially leading to high scrap rates and reduced competitiveness.
Continuous research, testing and process optimisation are therefore not optional—they are essential. This is where expertise becomes decisive.
Two paths, one mission
Mauro Canepa has spent more than four decades working with extrusion machines. At Bocchiotti in Arenzano, Italy, he has worked through every stage of the process—from production and quality control to machine technology and maintenance. When Bocchiotti became part of Hager in 2015, his experience became part of a much larger network. Today, Mauro sees his most important mission in passing that knowledge on to the next generation. His personal motto reflects his approach to the craft: “Pain, Patience, Passion”.
Hundreds of kilometres to the north, in Heltersberg, Germany, Christian Hartmann followed a different professional journey. He joined Hager in 2011—starting with an apprenticeship as a Process Mechanic for Plastics and Rubber Technology, specializing in moulded parts. He then continuously expanded his expertise through a 3,5-year cooperative study program with Hager/ Tehalit, completed with a Bachelor of Engineering specializing in Plastics Engineering and laboratory work in extrusion and system components. Since 2022, he has been Manufacturing Industrialisation Team Leader at Tehalit, responsible for bringing new extrusion profiles into series production. Christian’s focus is on simplifying processes and making them more robust - by translating expert know-how into automation and digital solutions. As he puts it: “Experts need to increase digital skills to support transformation and future technologies.”
Their backgrounds may be different, but Mauro and Christian share the same goal: improving plastic extrusion day by day.
Standardising excellence across sites
The core business of both sites lies in manufacturing electrical installation trunking such as slotted trunking, used within the Hager portfolio and across other group sites.
The collaboration between the two experts follows a simple but effective model: tools and solutions developed in Germany are tested on production lines in Italy and vice versa. Results and feedback are exchanged, improvements are made, and knowledge flows in both directions. This constant dialogue ensures that new ideas quickly become practical, reliable solutions.
It also enables the harmonisation of equipment and processes across sites, increasing flexibility, as both locations are able to manufacture identical products. A flagship example is the production of trunking profiles, like the GT45 and TR45 product lines, for the French tertiary market. Standardised tooling and machines as well as aligned processes have made this collaboration a joint success and a model for future projects.
Digitalisation plays a key role in this development. The introduction of “digital profiles” marks an important milestone for both locations. It enables full process traceability, comprehensive documentation, faster root-cause analysis and targeted optimisation. Beyond transparency, this creates tangible added value: processes can be continuously adapted to meet the needs of both internal and external customers.
Sustainability, one of Hager’s core priorities, is also seen as a matter of importance for the plants in Heltersberg and Arenzano. Both are committed to reducing waste and energy consumption by increasing the share of recycled content and continuously optimising tooling, process robustness and material selection. A key example is the CORP project, through which the teams are advancing the systematic recovery and reuse of internal and external materials.
Through the Eureka program, what once began as a competitive relationship has evolved into close and constructive collaboration.
Turning expertise into collective strength
The challenges ahead are significant. New extrusion lines require major investment decisions. Processes must become more standardized and sustainable. Digital technologies are transforming the way factories operate. At the same time, new generations of experts must be trained and inspired.
This is exactly where the Eureka program comes in. As Hager’s programme for technical and scientific expertise management, it connects specialists globally, recognizes their know-how, and fosters structured exchange. The experts work closely with Product Marketing & Engineering to ensure that technical expertise, product requirements and market perspectives are aligned from the outset.
By turning individual know-how into collective knowledge, Eureka creates a strong internal platform that preserves and continuously expands this knowledge. This enables teams to respond faster and more effectively to challenges in production and development, strengthening Hager’s innovation capacity and competitiveness.
Everything achieved is made possible by an outstanding team working across borders.
The sites in Heltersberg and Arenzano are proof that when knowledge is shared and solutions are developed together, the result is more than improved processes - it is a shared future.
For Mauro, being part of Eureka means ensuring that hard-earned experience is not lost. For Christian, it is a way to bring expert knowledge closer to the machines and into everyday production. The result is clear: better collaboration, stronger innovation, and a shared vision to shape tomorrow’s electrical world.
