Hello and welcome to a new post! The K trade fair in Düsseldorf once again proved itself as the ultimate meeting place for the plastics world—international, innovative, and truly immense. This year, I had the opportunity to witness some developments that are shaping the future of our industry, particularly in the areas of sustainability, digitalization, and advanced materials.
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| K Fair 2025: My highlights and discoveries |
My Key Discoveries:
🔹 China’s Growing Leadership:
Chinese plastics and rubber companies are not only increasing in number—up nearly 50% from the last event, now making China the second-largest exhibiting nation after Germany—but are also leading in innovation, product development, and circular economy initiatives. Their presence and technological advancements were truly impressive.
🔹 AI in Daily Production:
Artificial intelligence is no longer a buzzword; it’s now an integral part of daily operations. Connected machines and real-time data analysis are accelerating both the speed of innovation and speed to value across the industry.
🔹 Industry Transformation:
While revenue growth remains a challenge, this period is being used as an opportunity to streamline internal structures and consolidate portfolios, preparing for a more resilient future.
🔹 Energy Costs & Plant Closures:
High energy costs in Europe continue to impact the sector, leading to the closure of several chemical plants—a trend that cannot be ignored.
🔹 Recycling as a Sustainability Driver:
Recycling has evolved from a cost-saving measure to a key driver of sustainability, especially when combined with product carbon footprint passports and digital material twins.
🔹 M&A Activity:
Mergers and acquisitions remain active, with notable deals such as Engel’s acquisition of Trexel, a specialist in foaming technology for injection molding.
Let us deeper dive into the latest innovations in circular economy and recycling, digitalization and smart manufacturing, new materials, and machinery enhancements:
Circular economy and recycling innovations
Next-level recycling technologies: Companies like Gneuss showcased melt filtration and extrusion technologies designed to significantly improve recycling processes. The VDMA's Circular Economy Forum provided live demonstrations of implementing circularity within plastics production.
High-quality recycled materials: BioPlastics & Recycling GmbH presented certified post-consumer recycled (PCR) regranulates, including rPP and rPE with FDA approval, setting new standards for quality and sustainability.
Upcycled materials: Researchers showcased new materials, such as the BAETA technology, which transforms recycled PET bottles into carbon capture material.
Sustainable product design: Prototypes and commercial products were presented that were designed for better recyclability, including mono-material solutions and reusable systems. For example, Covestro and VAUDE introduced a recyclable, mono-material backpack made from TPU.
Innovative recycling technology: Syensqo showcased its innovative recycling technology for circular sulfone polymers.
Digitalization and smart manufacturing
Artificial intelligence (AI), the Internet of Things (IoT), and automation were on display to showcase the future of smart manufacturing.
AI for efficiency and sustainability: Exhibitors highlighted how AI-based process optimization can increase the throughput of blown film lines, automatically coordinating components for greater efficiency. Reifenhäuser also introduced "Reifenhäuser Next," a brand centered on an AI chatbot and digital learning platforms to combat skilled labor shortages and solve production challenges.
Digital twins: This technology was featured for creating virtual representations of production lines, allowing for the simulation and optimization of manufacturing processes before physical implementation.
Predictive maintenance: Advanced sensor technology and cloud applications enable the real-time monitoring of machinery, allowing for predictive maintenance that reduces unplanned downtime.
Digital Product Passports (DPP): In response to EU regulations, new technologies were presented to support the implementation of Digital Product Passports, which provide information on a product's raw materials, production processes, and recycling paths.
New and advanced materials
Sustainable polycarbonates: Covestro showcased its Makrolon® RE and Makrolon® RP polycarbonates, which incorporate recycled content or are based on renewable raw materials. These were used in applications ranging from electronics to medical devices.
Bio-based alternatives: The Fraunhofer Institute presented a new helmet made from bio-based polylactide (PLA), offering comparable protection to conventional helmets with a two-thirds reduction in CO2 emissions. Expanded PLA (EPLA) was also shown as a sustainable alternative to EPS foam.
High-performance materials for e-mobility: Complex busbars: Syensqo collaborated with Clayens to present a 360-degree approach for developing complex busbars for electric vehicles.
Recycled polyamide: RadiciGroup received an award for a battery module made from its recycled Renycle polyamide.
Machinery and equipment enhancements
Manufacturers introduced new and improved machinery that was faster, more efficient, and better integrated with digital systems.
First all-electric, tie-bar-less injection molding machine: ENGEL unveiled the new victory electric, its first all-electric, tie-bar-less injection molding machine, which combines their electric drive technology with their tie-bar-less design for increased efficiency and precision. The new machine is a world premiere that focuses on design advancements to meet specific customer requirements for greater benefits.
Smaller, faster machines: KraussMaffei introduced a process that compounds glass fiber rovings directly in the injection molding unit to reduce material costs. Netstal showcased its new-generation Elion MED series for medical technology, known for its speed and precision.
Simplified tool changeovers: Guill Tool & Engineering introduced its Cam-Lock system, designed to simplify tool changeovers on its extrusion heads.
Upgraded extrusion lines: Brückner presented its Greenline concept for film stretching lines, a new system for high-performance films, featuring a digital standard interface.
And of course, one of the true highlights: reconnecting with old friends and colleagues from across the plastics industry—the K Fair always feels like a family reunion!
Thanks for reading & #findoutaboutplastics
Greetings,
Literature:
[1] https://en.kunststoffe.de/k-fair#:~:text=Increase%20in%20Exhibitors%20at%20K,Fast%2C%20Precise%20and%20Reliable
[2] https://solutions.covestro.com/en/digital-event-space/kfair
[3] https://www.specialchem.com/plastics/news/syensqo-to-showcase-high-performance-polymers-portfolio-at-k-2025#:~:text=Syensqo%20will%20make%20its%20first,15th%20in%20D%C3%BCsseldorf%2C%20Germany.
[4] https://www.plastech.biz/en/news/Syensqo-to-debut-at-K-2025-with-specialty-polymers-portfolio-21142#:~:text=Partnerships%20and%20live%20program%20at,for%20single%2Duse%20surgical%20instruments
[5] https://www.k-online.com/#:~:text=K%202025%20focuses%20on%20key,be%20returned%20directly%20on%20site.
