Our Assembly and Testing Solutions for Media-Carrying Components – Conventional Fuels
We develop assembly and testing systems that enable you to reliably meet the increasing demands of your gasoline and diesel systems.
Modern fuel injection systems place high demands on precision, efficiency, and reliability. Components for gasoline and diesel systems must perform consistently under demanding operating conditions while meeting increasing requirements for emissions, efficiency and quality.
We develop innovative and highly specialized assembly and testing systems for fuel-carrying components. With our many years of experience and early involvement in the product development process, we find the optimal solution for each of your requirements.
Today, Sonplas is one of the leading global provider of assembly and testing systems for injection technologies.
Assembly and testing systems for diesel and gasoline injectors
End-of-line test systems for injection technologies
Flow and spray test systems for injector characterization
Injection quantity measurement for precise system analysis
ATEX test systems for fuel applications
Standards, safety and traceability
Assembly and testing systems for pumps
Solutions for development, validation and series production
Already interested?
Lukas Sepaintner and Matthias Kraml: “Let’s talk about your project!”
Contact us without obligation and tell us about your requirements. Together, we will develop the right solution—technically sound and precisely tailored to your needs.
Contact us!
Why Sonplas
is your ideal partner for conventional fuels
Specialist in fuel technology – today and beyond
While many market players have already moved away from combustion technology, we continue to invest specifically in innovations in the fuel sector. We develop highly specialized assembly systems and test benches for components that come into contact with gasoline or diesel. These systems are precise, reliable, and future-proof—making us one of the few providers that consistently advance this expertise today.
Maximum flexibility for your production
With our modular assembly and testing solutions, you receive systems that are precisely tailored to your requirements. From development to series production, you benefit from solutions that can be expanded, retrofitted, or adapted to changing production conditions at any time. We also specifically optimize and modernize existing systems to ensure your production remains efficient and future-proof.
Safe and ATEX-compliant testing
Our test systems are specifically designed for fuel applications and meet all explosion protection requirements in accordance with ATEX. This allows you to test your components safely, reproducibly, and in full compliance under realistic operating conditions.
Technical expertise from planning to final approval
Our expertise doesn’t end with the construction of assembly and testing systems. From the planning phase onward, we provide comprehensive guidance on technical requirements, safety regulations, and standards-compliant design. During implementation, we focus on every detail and actively support you throughout the official or internal approval process. This ensures your system is commissioned smoothly and operates without issues.
Test benches for ultra-high injection pressures up to 1,000 bar and beyond
Our systems are designed to meet current injection pressure requirements and enable pressures of up to 1,000 bar or higher. Each solution is developed precisely according to your specific requirements. Thanks to our flexible engineering approach, there are virtually no upper limits. Our test systems are built for the highest demands and have been successfully proven in numerous applications.
Reliable data for development and optimization
Measurements of injection quantities, flow rates, spray patterns, and other parameters provide detailed insights into the behaviour of your systems. This gives you a solid basis to specifically optimize the design, performance, and service life of your components.
How do our test benches and systems support your injection systems?
With over 30 years of industry experience and strong automation expertise, we develop precise and reliable solutions for testing fuel components. These include, among others:
- Injectors
- Injection pumps
- Nozzles
- Valves
- Fuel rails
- Pre-feed pumps
- and many other systems
In close collaboration with you, we design your testing process – individually tailored to your components, specifications, and the desired level of automation.
Which tests can we implement for you?
Our test benches capture all relevant parameters and characteristics of your systems, providing precise data on flow rate, leak tightness, spray pattern, as well as opening and closing times. For high-pressure pumps, we also enable reliable evaluation under realistic operating conditions, for example by measuring flow rate and operating pressure.
In addition, we carry out both functional and endurance tests on individual components as well as complete systems. For fuel applications, our ATEX-certified thermal chamber is available, enabling safe testing under controlled environmental conditions.
Left: Combined module for flow rate, spray pattern and leak testing
Center: Flow rate testing
Right: Leak tightness testing
Which assembly solutions can we implement for you?
Together with you, we develop system solutions that combine assembly and adjustment processes with inline and end-of-line (EOL) testing. In doing so, we bring together our 30 years of experience in injection technology with new and innovative technologies and our automation expertise.
Intelligent control systems, flexible buffering solutions, and continuous process monitoring ensure consistently high quality and minimal downtime.
Whether a single station or a complete system, integration into an existing line or a new installation: we are your ideal partner.
Our solutions
are in use worldwide
The global use of our solutions speaks for itself: today, several Sonplas injectors are produced every second worldwide, and every second high-pressure gasoline pump is tested on a Sonplas end-of-line test bench.
Left: Injector assembly line
Center: Injector overmolding
Right: Injector assembly line
Modern injection systems remain relevant – and we develop the right solutions to support them.
In the field of injection technology, Sonplas has been supporting its customers for over 30 years with precise assembly and testing solutions. Why this area continues to play an important role, what requirements modern injection systems must meet today, and why Sonplas is the ideal partner in this field is explained by Mr. Sepaintner.
Expert interview with
Lukas Sepaintner
Sales
Mr. Sepaintner, many manufacturers are moving away from combustion technology. Why does Sonplas continue to focus on this area?
Lukas Sepaintner: Because the market demands it—and that demand is growing. While many are focusing on electromobility, we are currently seeing a clear resurgence in demand for combustion engines, particularly in Europe, the US, and China. Modern injection systems, in particular, play a crucial role in improving efficiency and reducing emissions. Sonplas is one of the few suppliers continuing to actively invest in this area and we are among the “last men standing” in the industry.
How does this impact your machine solutions?
Lukas Sepaintner: We develop highly specialized assembly and testing systems for fuel-carrying components, such as valves, injectors, pumps, and pressure regulators. Our systems feature a modular design, are precisely tailored to customer requirements, and can be expanded or reconfigured at any time if needed.
How important is the combination of assembly and testing?
Lukas Sepaintner: Very important. We provide both assembly and testing from a single source, which saves our customers time, reduces coordination efforts, and eliminates unnecessary interfaces. The result is a seamlessly integrated, fully functional system that fits perfectly into existing production environments. This also gives our customers the advantage of having a single point of contact.
Are there technological limits when it comes to testing requirements?
Lukas Sepaintner: Practically none. Our systems currently operate with injection pressures of up to 500 bar, and we have already successfully implemented solutions for 1,000 bar and beyond on multiple occasions. Thanks to our highly flexible engineering, there are virtually no upper limits.
Do you have any questions? Contact us.
Our references
Solutions that speak for themselves
We understand what drives our customers
Frequently asked questions about conventional fuels
Thanks to our many years of experience and numerous successful projects we understand what drives you!
Do your systems comply with all relevant standards and certifications for worldwide use?
Yes. Our systems comply with international standards such as ISO, CE, IECEx, and ATEX and are designed in accordance with the applicable industry-specific regulations. We take country-specific requirements into account already during the design phase, ensuring that your systems can be operated safely and in full compliance worldwide.
We are increasingly working with alternative fuels – can Sonplas provide suitable test systems for this?
Yes. We develop test systems tailored to different types of fuels and alternative media. Thanks to our extensive experience with systems for fuels, hydrogen, and other media, we can also support your testing processes involving alternative fuels.
Here you can explore more about our solutions for alternative fuels!
We aim to operate more resource-efficiently. Can assembly and testing processes at Sonplas also be designed sustainably?
Sonplas focuses on minimizing fuel losses and optimizing test cycles to conserve resources and reduce emissions. In addition, we consistently use energy-efficient drives in our systems. For example, all pressure generation units are electrically operated. This ensures overall low energy consumption and supports sustainable testing processes.
