April 24, 2025 From e-Fuels to Diesel

Sonplas brings extensive expertise in testing fuel-contact components for all types of media.

For fuel technology, Sonplas produces both assembly systems and test benches for components that interact with fuels. The specialized machine manufacturer is focused not only on future-oriented technologies like hydrogen, e-fuels, and methanol, but also on traditional gasoline and diesel. This ensures that the mechanical engineering company continues to support its customers in sectors like automotive, off-highway, large engines, and aviation, maintaining long-term business relationships without leaving anyone behind. You will continue to receive comprehensive advice and solutions from a single source.

“Even though the topic of e-mobility has been pushed to the extreme in the automotive industry in recent years, fuels such as gasoline or diesel are by no means out of the picture,” Lukas Sepaintner is convinced. After all, the industry must retain the ability to choose which future mobility solutions to invest in. Sepaintner is a sales engineer at Sonplas. The mid-sized specialized machine manufacturer based in Straubing, Bavaria, now has nearly 30 years of experience in assembly and primarily in testing fuel-contact components in injection systems, such as valves, injectors, pressure regulators, fuel rails, injection pumps, and pre-feed pumps. As a service provider, Sonplas also offers the option to test the functionality and service life of hydrogen-carrying components on its own test bench, for example. The specialized machine manufacturer has its own in-house fuel laboratory for this purpose. Feasibility studies and product tests further enhance the range of services available to customers.

Typical processes include testing the flow rate, leak tightness, spray pattern, measuring opening and closing times, determining the injection rate, and testing the temperature. Both functional and endurance tests of individual components and complete systems are possible. The customers primarily include suppliers from the automotive, off-highway, large engine, and aviation sectors. “We design our test benches on a modular basis and can customize them precisely to meet the customer’s requirements,” explains the Sonplas engineer. “What sets us apart from our competitors is our ability to work with a wide range of media used in mobility, including gasoline, diesel, hydrogen, ammonia, e-fuels, methane, LPG, CNG, methanol, kerosene and even ethanol,” explains the Sonplas engineer. Since the test devices for the various fuels do not differ significantly, the specialized machine manufacturer has consolidated its expertise in fuel injection systems and offers customers a complete range of solutions from a single source. The experts at Sonplas are able to design various test benches based on the medium, including fuels that are subject to legal requirements for explosion protection. Sonplas uses actual fuels to ensure testing is conducted under real-world conditions. What matters is not just the expertise during execution, but also the guidance provided beforehand and the support during acceptance. This includes helping the customer integrate their test bench into their facility.

Sonplas offers support not only in developing complete test benches but also in optimizing existing systems. The experts focus on minimizing the cost of conversion measures. Thanks to the modular design, Sonplas can expand and retrofit devices as needed, such as when environmental conditions change. Units can also be omitted if they are not necessary. “This results in significant cost savings for the customer,” says Sepaintner.

On board right from the start

Sonplas is not only a dependable partner for testing components but also for developing the systems and components themselves. “By getting involved early in the process, our technicians find the most efficient solutions during product development,” assures Sepaintner. Their requirements vary, for example, in terms of material compatibility, seal selection, or the size of the holes through which the cables are routed.

Sonplas offers both assembly and testing from a single source, efficiently integrating both disciplines into its solutions. With a proven network of carefully selected and reliable partners, users receive a comprehensive package and have only one point of contact. This streamlines communication, reduces organizational effort, and minimizes interface issues. “We know precisely what matters when it comes to components,” says sales engineer Sepaintner with conviction. “This ensures we are always on the same level as our customers, which is a significant added value.”

IAV Cross – Injection Analyzer

For injectors in combustion engines and for all other media such as hydrogen, ammonia, e-fuels, methane, LPG, CNG, methanol, kerosene, water, or ethanol, Sonplas offers a solution with the IAV Cross – Injection Analyzer. This device measures the injection rate by detecting the dynamic pressure increase in a fuel-filled measurement channel. It can measure both injection rates and quantities individually and simultaneously and display the rate signal with high precision. Since the system has no moving parts, it requires minimal maintenance and provides consistent, reproducible results. The measuring unit is controlled by advanced software that is user-friendly and provides a clear, real-time display of all relevant information. Users can also connect the IAV Cross – Injection Analyzer by Sonplas to their test bench software via a software interface, seamlessly integrating it into their digital test and development environment.

Sonplas GmbH:
Sonplas is a medium-sized mechanical engineering company headquartered in Straubing, Lower Bavaria. Since its establishment in 1993, the company has experienced steady growth. Sonplas now employs approximately 390 highly motivated staff members. In alignment with the motto “For your success”, Sonplas specializes in developing flexible and scalable specialist machines for processing, assembly, and testing. These can be complemented with external technologies as per the customer’s specifications. Over the years, the portfolio has consistently grown, and the specialist machine manufacturer now provides solutions for various sectors including electromobility, battery cell production, hydrogen technology, hydro-erosive machining, fuel injection, electronics, mechatronics, hydraulics, and aerospace technology. To date, the company has delivered over 1,000 specialized machines worldwide to renowned clients in the automotive, automotive supply, commercial vehicle industries, and aviation technology sector.

With its in-house research and development department, Sonplas consistently meets the latest technical demands in the market. With service partners worldwide and a subsidiary in China, the company also provides customers with expert support and spare parts directly on-site. What sets Sonplas apart? Sonplas is distinguished by its profound expertise and comprehensive understanding of processes. Acting as both a system integrator and general contractor, Sonplas provides customized, high-quality solutions to its customers.

Images Source: Sonplas GmbH

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