Global regulation regarding sustainability and energy consumption creates a difficult challenge to overcome for the plastics industry. Simultaneously, the increasing demands of complex processes to produce high-quality parts obscure the interrelation between process parameters and material behavior. Manufacturers have the opportunity to embrace the technological possibilities that enable an increase in quality, productivity, and sustainability. An industry case study shows how the sensXPERT in-mold sensor solution tackles these challenges using real-time material characterization and data analytics. The result is an immediate improvement in waste reduction, cycle time optimization, and a decrease in energy costs per part.