Igus training factory to end shortage of skilled workers

Igus in Cologne Porz-Lind has been creating innovations from high-performance plastics for over 60 years, whether it be lubrication-free plain bearings, smooth-running ball bearings, robust energy chains, flexible cables or cost-effective robots. To ensure that over 4,000 orders can be sent from Cologne to customers worldwide every day, the company relies on training its own mechatronics technicians, toolmakers and cutting machine operators, electronics technicians and plastics and rubber technologists. Until now, trainees at Igus have learned separately in the respective departments. From now on, they will have their own 378 square meter training factory at their disposal, equipped with lathes and milling machines, five injection moulding machines and electrical workstations. However, the trainees remain integrated into the value chain. They take on real customer orders, such as the repair of injection molding tools and the production of small orders. The young specialists also learn directly how to use AI and robotics in their work tasks.

This is made possible by the in-house automation department and the company's own low-cost automation division, which Igus uses to develop cost-effective automation solutions for industry. "At the same time, the trainees can learn in a more concentrated way in the training factory," says Dr. Thilo Schultes, CEO Operations at Igus. "Learning together and regular exchanges strengthen both the cohesion between the training professions and motivation." After a year and a half in the training factory, the trainees move to their respective specialist departments.

Number of trainees grows by almost 42 percent

Igus' goal is to train the skilled workers it needs itself and to become independent of the external labor market in the long term. "The new training factory, in which we have invested around 600,000 euros, not only offers us new capacities, but also makes us less dependent on external training centers and their machinery," explains Michael Köllen, Head of HR Production & Technology. "This allows us to train our specialists independently at an early stage on state-of-the-art machines in accordance with our own quality standards."

The goal is ambitious: From 2027, the company wants to cover its entire need for skilled workers itself. An important step towards this has already been taken. "25 new apprentices started their first year of training in September 2025, an increase of around 42%," explains Michael Köllen. A total of 59 young people in all apprenticeship years are currently undergoing their training at igus in the industrial-technical field. Igus will be looking for new apprentices again from October for the 2026 apprenticeship year.

Adult education with the IHK

Igus has been working with the Chamber of Industry and Commerce since 2016 to enable people at every stage of their lives to undertake further training. Together, courses have been designed that enable non-specialists or employees without vocational training to obtain recognized Chamber of Industry and Commerce qualifications. Currently, 38 employees are completing such a course. Over 250 employees have already graduated and have been trained as specialists with a corresponding focus on injection molding, machining, extrusion, logistics or assembly.