From acquired moulds to global standard: the partnership between PION Cable Protection and HSV TMP

This article was written with the assistance of Gerben Borger, founder and director of PION Cable Protection.

What should you do if you acquire a complete set of injection moulds with almost no information about their condition?

For many companies, this would be a risk. But for PION Cable Protection, it was actually the starting point for a strategic partnership with HSV TMP.

That partnership has since delivered the world’s strongest multiduct in its category: the Utilis. It is made from fully recycled material, has an official environmental declaration and is now used for critical infrastructure across the world. The Utilis is used from Scandinavia to Paris, but also closer to home for cables under the platforms of Amsterdam Central Station and to protect a fibre-optic connection in the districts of Waterrijk and Biezenlanden in the municipality of Alphen aan den Rijn.

That success is all down to a partnership based on technical knowledge, transparency and mutual trust.

We spoke to Gerben Borger, founder and director of PION Cable Protection, about how the partnership came about, the technical challenges faced and why he is very happy to recommend HSV TMP to other companies with similar challenges.

From PION Plastics to international presence

PION has undergone a major transformation and has adopted a fundamentally different course. The company, which was founded in 2023 as PION Plastics, has operated since last year under the name PION Cable Protection. The company develops and supplies high-quality systems for the underground protection and orderly routing of cables and piping: critical infrastructure. These products are used in civil engineering, rail, energy, telecom, datacentre, industrial and utility applications.

An ambitious change of course

The company previously supplied a wide range of products, but has now chosen to focus on its own fully in-house production lines and international growth through a network of distributors. PION is now active in eight countries, and aims to expand further globally.

This international strategy was a deliberate choice. PION has chosen to focus more and more on its own product groups and the production partners that actually make these products, with direct marketing being gradually transferred to distributors. This change of strategy was driven by entrepreneurship, and demanded a production partner that did not just offer capacity, but also actively contributed to discussions about quality, scalability and future growth. Gerben sums it up succinctly: ‘A combination of gut feeling, market knowledge, resilience and courage.’

The challenge: to produce large injection moulded products with existing moulds

An important element of the new strategy was the acquisition of several existing injection moulds for the Utilis multiduct. The heaviest of these large injection moulded products weighs no less than 18.2 kg.

This seemed a logical step, but immediately led to technical challenges. The moulds had not been developed by PION and little was known about their technical condition. The large moulds were transported to HSV TMP in two trucks for inspection. That was the moment the partnership really got started.

It quickly became apparent that maintenance on the moulds was overdue and that some parts required modification for use on the production lines. Thanks to HSV TMP’s approach and the positive impression made during the first meeting, PION quickly reached a decision.

Step by step towards a working production line

First analysis, then production: a structured development process

Instead of immediately starting production, HSV chose a structured development process: each mould was individually inspected and evaluated, which resulted in an extensive report with photos, technical findings and a clear cost estimate.

During joint meetings, the required modifications to optimise the moulds for HSV TMP’s production facilities were discussed. This transparency gave PION the confidence to invest further.

More than a manufacturer

Since then, the partnership has reached a new phase: the development of a new accessory. HSV brought BPO, one of its partners, to the table to provide support with product development, design and mould optimisation. This resulted in a better design, a more efficient production process and a firm foundation for future expansion of the PION range. The definitive version of this promising solution is expected in a few months.

This shows what HSV TMP stands for: playing an active role in strategic discussions, from the first idea to series production.

A product that performs across the globe

The combination of its size, dimensional tolerances and durability make the Utilis multiduct unique. The product can be used worldwide and functions without problems in a wide range of situations, from extreme cold in the north of Scandinavia to the heat of the Middle East. Thanks to its dimensional stability, it also fits perfectly with the range of matching accessories.

The result: the strongest in its market

All in all, the result is impressive: the Utilis multiduct has a higher ring stiffness class than any similar solution in its market and is made from fully recycled materials. The Utilis contributes to protecting critical underground infrastructure and keeping it operational, as mentioned previously in this article. In this way, it helps our society to continue functioning, so that everyone can work, live, travel and stay in contact.

This year, the products will roll off the TMP production lines in Ede and Leeuwarden for use in projects including a rail line extension at the world’s largest underground iron ore mine, e-charging projects in Norway and a datacentre in the north of Paris.

Sustainability without concessions

While suitability often comes at the cost of performance, PION has shown that the opposite is possible. PION products are made from 100% post-consumer recycled plastic, without affecting the expected service life of around 100 years. To objectively demonstrate these sustainability claims, PION has completed the following official processes:

• Life Cycle Analysis (LCA)
• Environmental Product Declaration (EPD)
• Environmental Cost Indicator (ECI)

HSV supplied important data to assist with these processes, which means PION complies with increasingly strict sustainability standards for national and international infrastructure projects.

More than a production partner

According to PION, HSV TMP stands out not just because of its facilities for the production of large injection moulded products, but also its approach to partnership: from the initial phase, they look beyond production alone by devoting attention to the various ways of investing in the partnership.

To strengthen relationships with clients, PION and HSV TMP have made joint visits. Discussions have been held about stock management, optimal production run sizes and delivery security. All this gives PION the capacity to deliver from stock, which enhances their position in the market. ‘Given these experiences, I am very happy to recommend HSV TMP’, says Gerben.

The next step
Looking to the future: international growth and expanded product range

PION has major ambitions for the future. If their plans are implemented as expected, a major investment will be made to expand the product range and create extra production capacity.

The first new accessories have already been developed and the moulds have been ordered. The product range expansion will continue later this year, with the involvement of both PION and TMP. HSV TMP profiles itself as a strategic production partner for innovation, mould technology, series production and logistics support.

Partnership Is Our Nature

It is no coincidence that PION stands for Partnership Is Our Nature. This is one of the company’s core values. Long-term partnerships, based on mutual respect, understanding and wishing the other party to succeed too are at the heart of what the company stands for.

According to Gerben, this partnership is more than just a technical success – it proves that entrepreneurship is all about vision, courage and long-term relationships. Gerben’s advice for other companies facing a similar challenge: ‘Make sure you work towards your goals with the right energy. Be aware that the result will come, even if you can’t see it yet. Trust your instinct, knowledge and commitment.’

Would you like to know more?

Does your organisation face a similar challenge? Would you like to find out how we can optimise your product or improve the production process for your large plastic product? Don’t hesitate to contact us +31 (0) 318 – 648 991 for a discussion without obligation.

From the first technical challenge, we can help you answer questions about manufacturability, mould optimisation, material choices, series production and logistical solutions.

Frequently asked questions

What makes the Utilis multiduct from PION Cable Protection special?

The Utilis multiduct has the highest ring stiffness class in its market segment, is made from fully recycled material (post-consumer waste) and is officially EPD verified, including LCA, and has an ECI.

In which sectors is the Utilis multiduct used?

The Utilis is used worldwide for rail, energy, datacentre, port, airport, road, telecom and utility applications for the underground protection and orderly routing of cables and piping. It contributes to protecting critical infrastructure and keeping it operational to allow society to continue to function, so that everyone can work, live, travel and stay in contact.

Why did PION choose HSV TMP as their injection moulding partner?

HSV TMP has facilities for the series production of large plastic products, expertise in injection moulding and knowledge of complex moulds. The pleasant contact and strategic partnership in production, product development and logistics were an added bonus.