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BUSINESS INSIGHTS | LATEST TRENDS | FUTURE PROSPECTS

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SPOTLIGHT PLASTICS SHAPE THE FUTURE!

Mold Your Dreams mold your future!

Materials, Process & ENERGY!

FUTURE OF PET RECYCLING!

fasicinating HIGHLIGHTS @ Fakuma 2024!

MULTI COMPONENTS injection moulding!

AI in the Plastics Industry!

BUSINESS INSIGHTS | LATEST TRENDS | FUTURE PROSPECTS

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Injection Molding Machine Market Trends The global injection molding machine market size was estimated at USD 15.99 billion in 2023 and is projected to grow at a CAGR of 4.7% from 2024 to 2030. The market has witnessed significant growth in recent years, driven by the rising demand for molded plastic products across various industries. Injection molding machines play a crucial role in the manufacturing process by injecting molten material into a mold, resulting in the production of a wide range of products with high precision and efficiency.

Key factors driving the market growth are the increasing adoption of plastic components in automotive, packaging, consumer goods, and medical sectors. These industries require mass production of intricate parts, which can be efficiently achieved through injection molding, thus boosting the demand for injection molding machines. The rising demand for on-the-go packaged products in the U.S. owing to the increased purchasing power and the busy lifestyle of consumers is expected to have a positive impact on the market growth of the packaging industry in the country. The flourishing packaging industry and the rising adoption of injection-molded packaging products are anticipated to drive the demand for these products in the U.S. over the forecast period.

Technological advancements in injection molding machines, such as the integration of automation and robotics, have further enhanced their efficiency, accuracy, and productivity. Manufacturers are investing in the development of advanced machines equipped with features like real-time monitoring, predictive maintenance, and energy efficiency, thereby driving market growth. The growing emphasis on sustainability and environmental concerns has led to the adoption of eco-friendly materials and processes in manufacturing. Injection molding machines are increasingly being used with biodegradable and recycled materials, aligning with the global shift towards sustainable practices and contributing to market expansion.

Rising population and improving economic conditions create high demand in consumer goods and food & beverage industries. This poses high competition for manufacturers, creating need for product differentiation with attractive packaging which results in a high growth rate for complex, high-quality packaging products. These factors are expected to drive the market growth over the forecast period. Fluctuations in the prices of raw materials, such as plastics and metals, pose a significant threat to the injection molding machine market. Sudden price increases can impact production costs and profit margins for manufacturers, affecting competitiveness in the market. Rapid advancements in technology, such as additive manufacturing and alternative molding processes, present a threat to traditional injection molding machines. These disruptive technologies offer advantages in terms of speed, flexibility, and cost-effectiveness, potentially displacing conventional injection molding methods and machines.

Electric machines rely on electric servo motors for movement, offering higher precision, faster cycle times, and energy efficiency compared to hydraulic machines. The market trend towards electric machines is driven by increasing demand for precision and sustainability, as well as advancements in electric drive technology enabling improved performance and reduced operational costs.

Founder Editor-in-Chief Late Mr. Kanwar NS Editors Amrita Kanwar Sarvjit Singh China Correspondent & Reporters Ying Wei-Beijing Bao Tian Tian - Shanghai Xing Guang Li - Guangzhou Assistant Editor/Correspondent Elena Secretary & Legal Advisor Aaron Kumar Circulation Surekha Gogna Production, Design & Degital Media Rakesh Sharma Marketing & Sales Lina Catherine Amy Lan Anna Mi Technical Advisors Alex Van Bienen/Lily - Nederlands Public Relations Director (UK) Mike Steele Advisor Internet Richmond Kanwar International Advisor (Australia) Andrew S. McCourt Germany Representatives Julia Rittershofer Steffen Schnaderbeck India (Head Office) C2073A Sushant Lok 1, Gurgaon 122 002 Tel: +91 9999489614 info@polymersandrubbermatters.com www.polymersandrubbermatters.com

The 29th Fakuma presents “Mold your dreams, mold your future”

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rickenhausen, Germany – 04 June 2024 – The organizer Schall Messen and the advisory boards of the Fakuma trade fair, one of the most internationally renowned events for plastics processing with a special focus on injection moulding, are pleased to announce the launch of their latest initiative project “Mold your dreams, mold your future”.

As part of this inviting campaign, the Fakuma trade fair is organizing a special Career Friday aimed at introducing school pupils, students and young professionals to the wide range of career opportunities in the plastics industry. The event will take place on 18.10.2024 as part of the 29th Fakuma at the exhibition grounds in Friedrichshafen.

Career Friday offers school pupils, students and career starters the unique opportunity to visit the international exhibitors at the Fakuma trade fair at their stands and find out more about the exciting career opportunities in the plastics industry. Under the motto “Mold your dreams, mold your future”, exhibitors will give young visitors career insights into the world of

plastics processing, product development and innovative technologies. The plastics industry is a vibrant hotspot for innovative ideas and technological advances. With a clear focus on the circular economy, it opens up exciting opportunities for pupils, students and young professionals to actively contribute to sustainability and help shape the world of tomorrow.

“Our aim is to inspire young people to pursue a career in the plastics industry and show them how diverse and exciting this sector is,” says Bettina Schall, Managing Director of event organizer Schall Messen. “Career Friday offers a unique opportunity for pupils, students and young professionals to talk directly to industry experts, gain insights into innovative technologies and explore potential career paths.”

Trade fair advisor Susanne Zinckgraf, Head of Strategic Marketing at WITTMANN Tec Group GmbH, emphasises: ‘Plastics are essential to life. Without plastics, there would be no modern medical technology, no sustainable mobility and no respectful handling of food. A career in the plastics industry means

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actively helping to shape the future of our society. That is why we are looking forward to giving young people an insight into our activities at Fakuma 2024. Career Friday is a great opportunity. Nowhere else can you get closer to the industry than at the Fakuma trade fair.’

The industry is heavily characterised by digital technologies, which offers exciting opportunities for techorientated people. It also carries a great deal of responsibility for environmental and health issues, which requires conscious action.

Industry players are working intensively on sustainable alternatives and recycling technologies. The exhibitors’ collaboration with partners around the world offers young talents the opportunity to gain intercultural experience and tackle global challenges as part of a team.

Exhibition Advisory Board member Dr Christoph Schumacher, Head of Global Marketing at ARBURG GmbH + Co KG, adds: ‘The future needs ideas – and people who develop and implement them. Our industry offers many tremendous opportunities to get personally involved in

solving important issues: the ‘purpose’ that is often invoked today is clearly evident here. If you want to shape things, our industry is the right place for you! This is why ARBURG, as a historic pioneer of the Fakuma, expressly supports this idea. We look forward to welcoming as many young, interested visitors as possible.’

The 29th Fakuma cordially invites all school pupils, students, teachers, university representatives and young professionals to visit the trade fair highlight free of charge on Careers Friday and discover the world of plastics processing.

About the Fakuma trade fair: The Fakuma trade fair is one of the leading international trade fairs for plastics processing and occupies a leading position worldwide in the field of injection moulding. This year, from 15 to 19 October 2024, it will once again offer a unique platform for presenting innovations, sharing know-how and networking with industry experts from all over the world under the motto ‘digital meets circular economy’.

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Masterbatch Development with New Stretching Machine LyondellBasell integrates KARO® 5.0 from Brückner Maschinenbau to boost R&D Capabilities

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yondellBasell, a prominent player in the chemical industry, has recently integrated the stateof-the-art KARO® 5.0 laboratory stretching machine from Brückner Maschinenbau into its research and development facilities at the LYB Technical Center in Akron, Ohio. This strategic enhancement is set to significantly advance the company's ability to develop and test masterbatch solutions tailored for various oriented film applications.

Advancing Masterbatch Innovation The KARO® 5.0 machine marks a pivotal advancement in LyondellBasell's research capabilities, allowing for more precise and efficient development and testing of masterbatch solutions. "This advanced technology will allow us to accelerate the development of new and improved masterbatch solutions, ultimately helping our customers bring their products to market faster and with greater confidence," stated Tiago Piccoli, LYB Director of APS PAD for Consumer & Industrial Markets in the Americas.

Multi-Cast Film Capabilities: Allows testing a broader range of masterbatch materials.

Dual Direction Stretch: Provides stretch capabilities in both the machine direction (MD) and transverse direction (TD), closely simulating real-world production conditions. Comprehensive Monitoring: Tracks various material characteristics such as tension, elongation, torque, temperature, and thickness to ensure top performance and quality.

Enhanced Speed-to-Market By enabling a closer match to masterbatch materials used in actual production processes, the KARO® 5.0 significantly reduces the time

Key Features and Benefits of KARO® 5.0 The KARO® 5.0 stretching machine is equipped with multiple cuttingedge features that enhance the testing and development process:

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required to bring new products to market. It enhances LyondellBasell's speed-to-market process, offering customers the ability to rapidly identify and select the optimal masterbatch for their specific needs.

Global Impact and Technical Leadership "The addition of the KARO® 5.0 reinforces our technical leadership and commitment to innovation in the masterbatch industry," commented Chuck Hampton, LYB Director of Masterbatch and Colors U.S. & Canada. The new technology not only complements LYB's testing assets in Europe but also extends its advanced R&D capabilities to the Americas, benefiting global customers with innovative masterbatch solutions.

Supporting Diverse Applications The KARO® 5.0 supports LYB's Advanced Polymer Solutions (APS) and Olefins and Polyolefins (O&P) business segments by enhancing product development for applications such as protective films and food packaging.

Testing with the new equipment is already underway, showcasing LyondellBasell's dedication to creating advanced solutions that cater to a diverse range of industry needs.

Materials, Processes, Energy: the Focus is on Efficiency at Fakuma 2024

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he industry will meet in Friedrichshafen for the 29th Fakuma international trade fair for plastics processing from the 15th through the 19th of October, 2024.

For many companies, the autumn highlight is one of the most important trade fairs and will once again be a celebration of plastics.

Career Friday will take place for the first time this year with the objective of inspiring young people for careers in the plastics industry. The “Fakuma Roundtable” will be held for the second time, addressing this year’s topic of “Digitalisation – Top or Flop?”

Efficiency will be a key topic at Fakuma 2024 – on several levels and from a variety of perspectives.

Increased efficiency in terms of materials and energy consumption is

crucial, as are process efficiency and the efficient operation of production systems, because in light of current shortages of qualified personnel, consistently high levels of quality can only be achieved reliably and efficiently with easy-to-use control systems and digital assistance. As a result of the new Energy Efficiency Act, German plastics processors will be challenged to a much greater extent to realise their full potential.

Fakuma exhibitors will provide tools and solutions for the challenges of efficiency, the conservation of resources and sustainability.

Career Friday for Pupils, Students and Entry-Level Employees Career Friday for pupils, students and entry-level employees will be a

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new feature this year in keeping with the motto “Mould Your Dreams, Mould Your Future”. Together with the trade fair advisory board, trade fair promoters P. E. Schall are launching this campaign to inform young people about a broad range of career opportunities in the plastics industry. The event will be held as an integral part of the trade fair on the 18th of October, 2024.

Career Friday will provide the target group with the unique opportunity of meeting Fakuma’s international exhibitors in person at their booths and finding out first-hand about exciting career prospects. The exhibitors will offer young visitors insights into the world of plastics processing, product development and new technologies. In dialogue with industry experts, interested parties will receive exciting

background information on plastics processing and insights into work processes. Career Day will reveal practical opportunities for vocational training and career options.

Furthermore, the “Mould Your Dreams, Mould Your Future” campaign is a tremendous initiative, because nowhere else do young people and potential employers come closer together than directly at the trade fair.

Collaborations pursued by the exhibitors with partners all over the world provide talented young people with the chance of gaining intercultural experience along their career paths and tackling global challenges as part of a team. And thus the 29th Fakuma invites all pupils, students, teachers, university representatives and young profes-

sionals to visit the trade fair highlight free of charge on Career Friday, and to discover the world of plastics processing.

World-Class Panel to Discuss Digitalisation at the Roundtable This year’s Fakuma Roundtable is further highlight which focus on digitalisation in plastics processing on Tuesday the 15th of October at 4 p.m. The discussion is entitled “Digitalisation – Top or Flop?”, and will examine the question of which digital tools really help the plastics industry. Panellists including professor Dr. Braungart, founder and scientific director of BRAUNGART EPEA, Philipp Lehner, chief executive officer of the ALPLA Group, Guido Frohnhaus, director of technology at Arburg, Professor Dr.-Ing. HansJosef Endres from the Institute of Plastics and Recycling Technology at Leibniz Universität Hannover and professor Thomas Seul from Schmalkalden University of Applied Sciences will discuss the current level of digitalisation in the industry,

as well as what still needs to be done. The discussions are also intended to reveal the extent to which digitalisation can solve the challenges faced by the industry, i.e. sustainability and the shortage of qualified personnel. The Fakuma Roundtable will be moderated by Dipl.-Ing. Markus Lüling, editor-inchief at K-Profi. All interested parties are cordially invited to attend the discussion – participation is free of charge.

Exciting Innovations Expected in the Field of Injection Moulding Technology The overall focus of Fakuma is thus on digitalisation, automation, flexibility, energy efficiency and sustainability. The establishment of closed-loop material flows, product optimisation targeted at recycling and the processing of recyclates for high-end applications will also be at the top of the agenda this year.

Innovations in the field of injection moulding technology are being eagerly awaited – systems with allelectric drives that make machines

flexible and powerful, and raise them to a new level of efficiency.

Fakuma will also provide new impetus for the aspects of holistic product design and the further development of recycling and degradability.

fairs. The industry highlight retains its relaxed atmosphere, even with high levels of internationality. Fakuma’s typical expert visitors are highly professional, thus making it possible to engage in intensive, top-quality discussions.

Design for recycling – this goal is taking shape to an ever-greater extent in product manufacturing.

Future-proof solutions for packaging, recycling compounds and alternatives to metal are therefore just as much in focus at the trade fair as machines for grinding and crushing, cooling systems and energy-efficient mould temperature control technology, systems for process monitoring and data acquisition, as well as innovations from the field of industrial 3D printing. The increasing use of renewable instead of fossilbased raw materials will also be a key topic.

They value the trade fair’s thematic focus on their own needs and requirements. Plastics processors get concrete answers to their questions at the event and find out how they can improve their operations, increase their efficiency and strengthen their business resilience.

Fakuma is a genuine working trade fair – pragmatic and highly practical.

The tried-and-tested format is highly esteemed by all involved parties.

Fakuma: One of the Most Important Working Trade Fairs For many companies, Fakuma is one of the world’s most important trade POLYMERS & RUBBER MATTERS | OCTOBER 2024 | 11

Flying high and more: fascinating highlights at Fakuma 2024!

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his year’s Fakuma, the international trade fair for plastics processing, will be reaching new heights in the literal sense of the word from 15 to 19 October 2024: For example, Career Friday participants can win one of two vouchers for a 60-minute zeppelin flight for two. The programme also includes other attractive highlights: the second edition of the ‘Round Table at Fakuma’ discussion format, this time on the topic of ‘Digitalisation – Top or Flop?’, a future-oriented start-up area, an exhibitor forum with topclass expert presentations and the presentation of the ‘cradle to cradle’ design concept at the opening press conference. The plastics processing industry is looking

forward to the highlight of the autumn – Fakuma 2024 in Friedrichshafen, Germany. It will be the 29th iteration of this international trade event, which is one of the most important trade fairs of the year for many companies. The industry highlight in the form of a hands-on trade fair maintains a familiar atmosphere with a high degree of internationality. ‘Last year, we welcomed 1,636 exhibitors from 40 countries in twelve halls, with foreign participants making up 38 per cent, and similar numbers are expected this year,’ says Annemarie Schur, Fakuma project manager for exhibition organiser P. E. Schall.

‘Twelve halls plus the two East and West foyers will be in use for the event. As always, Friedrichshafen will

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be packed and we’re looking forward to it!’

Career Friday: Discover plastics processing and win a zeppelin flight For the first time this year, the

exhibition organiser, the exhibitor advisory board and the exhibitors are organising a Career Friday for pupils, students and young professionals under the motto ‘Mould your dreams, mould your

future’. The campaign aims to inform young people about career opportunities in the plastics industry and teach them about plastics at the same time. ‘Plastics are enormously important. They are indispensable and they also offer career opportunities – this is what we want to talk about on Career Friday,’ explains Bettina Schall, managing director for exhibition organiser P. E. Schall. ‘The exhibitors will provide young visitors to the trade fair with an insight into the world of plastics processing, product development, new technologies and work processes.

This will spark a great deal of enthusiasm for plastics and people will want to get involved in this industry of the future,’ says the trade fair manager confidently. ‘All pupils, teachers, students, young professionals and young people are cordially invited to visit Fakuma on 18 October 2024!’ As many of the target audience as possible are encouraged to attend, as a spectacular flight awaits: participants of the career information day can win one of two vouchers for a 60-

minute zeppelin flight for two. The winners will be drawn on 18 October at 4pm.

The campaign is already taking shape. Plastics Europe Germany is preparing a guided tour: the theme is ‘Circular Economy’, and takes participants on a tour of the trade fair along the entire value chain from granulate to product and back again.

Participants can expect many exciting encounters on their journey.

‘Round Table at Fakuma 2024’: Experts discuss digitalisation Another highlight of this year’s trade fair is the second edition of the ‘Round Table at Fakuma’ on Tuesday, 15 October 2024 at 4pm. This time, the panel will be discussing digitalisation in plastics processing.

Under the heading ‘Digitalisation – Top or Flop?’, a select group of experts will discuss which digital tools can really help the plastics industry meet the challenges ahead.

The five panellists, Prof. Dr Michael Braungart, founder and scientific

director of BRAUNGART EPEA, Philipp Lehner, CEO of the ALPLA Group, Guido Frohnhaus, Managing Director for Technology at Arburg, Prof. Dr-Ing. Hans-Josef Endres from the Institute of Plastics and Circular Economy at Leibniz University Hanover and Prof. Dr-Ing. Thomas Seul from the Schmalkalden University of Applied Sciences, will assess the state of digitalisation in the industry. The panel will examine the extent to which digitalisation offers solutions in the areas of sustainability and the shortage of skilled workers. The Fakuma roundtable will be moderated by Dipl.-Ing. Markus Lüling, editor-inchief of K-Profi. All interested parties are invited to attend the discussion; participation is free of charge.

Future-oriented topics – Startups with novel approaches Fakuma will also give new impetus to the goal of sustainability. This means designing products holistically and promoting recycling and degradability. ‘Design for recycling’,

for example, is becoming more tangible in the way products get made. The increasing use of circular rather than fossil raw materials is also a key aspect. Sustainable solutions for packaging, recycling compounds and metal substitutes will be on show, as will grinding and crushing machinery, cooling systems and energy-efficient tool temperature control technology, process monitoring and data acquisition systems, and innovations in industrial 3D printing. Trade visitors can expect to see ground-breaking ideas on how to tackle the specific challenges facing the industry in the start-up area and exhibitor forum.

Fakuma has traditionally been a platform where processors can get answers to their questions and learn how to improve their operations and position themselves optimally for the future.

The big goals: greater efficiency and sustainability Efficiency is clearly a key focus at Fakuma 2024 on several levels: even

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Artificial Intelligence in the Plastics Industry: Sustainability through Technology How Algorithms are supporting the Industry today

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rtificial intelligence is revolutionising modern industry. Thanks to it, complex processes can be automated, efficiency increased and further innovations made possible.

In the plastics industry, AI not only plays a decisive role in the optimisation of production processes and the development of new materials. It also enables more precise waste sorting and therefore better recycling – a win for the environment!

A brief history of AI Ideas about artificial intelligence date back to the early 20th century, when scientists began to consider the possibility of developing machines that could exhibit human-like intelligence. The modern era of AI began in the 1950s with the development of the first models, including Alan Turing's Turing test and Frank Rosenblatt's neural network. In the 1960s and 1970s, some successes were achieved in AI, including the development of expert systems. However, disappointments also followed when many early approaches failed to deliver the expected results. In the 1980s, AI experienced a boom with the development of algorithms such as the backpropagation algorithm for neural networks and the support vector machine algorithm. Knowledge-based systems and expert systems became popular in the 1990s. These systems used rules and databases to make human-like decisions in specific domains. The algorithms make it possible to recognise patterns in large data sets and to model complex relationships. From the 2000s onwards, AI experienced a further boom due to advances in machine learning and data analysis. Today, advanced AI technologies such as machine

learning, image recognition and natural language processing are used in various areas of daily life.

Companies are using AI to increase efficiency, reduce costs, drive innovation and develop sustainable solutions.

promotion of the Circular Economy in various ways: Recycling optimisation: AI can make the recycling process more efficient, for example by controlling robots in recycling plants to sort and process plastics more effectively.

Areas of application for AI in the plastics industry

Material identification: With the help of AI, plastics can be precisely identified, making it easier to sort recyclable materials and improving the quality of the recycling process.

Artificial intelligence has a wide range of applications in the plastics industry: Process optimisation: AI can be used to optimise production processes and reduce energy consumption and waste. By analysing operating data and sensor data, algorithms can recognise patterns and make recommendations to improve efficiency. Material development: AI can help in the development of new materials and compositions by applying simulation-based design methods and analysing large amounts of data to identify optimal material properties.

Quality control: AI can be used in quality assurance to detect defects or irregularities in plastic products by analysing images or sensor data. This can help to identify faulty products at an early stage and improve production quality. Production planning and management: AI can be used in production planning and management to improve demand forecasting, optimise supply chains and manage stock levels. This helps to avoid bottlenecks and increase the efficiency of the entire production process. Waste management: AI can help with the sorting and identification of plastic waste by using image recognition technologies and machine learning. This enables more efficient sorting and recycling of plastics, which helps to promote the Circular Economy.

The contribution of artificial intelligence to sustainability Artificial intelligence can support the

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Design optimisation: With the help of AI, plastic products can be designed in such a way that they are easier to recycle or can be made from recycled materials. This helps to reduce waste and promote a closed Circular Economy. Sustainable production processes: AI can be used in production facilities to minimise energy consumption and material waste by optimising processes and using resources more efficiently. Forecasting and analysis: By analysing large amounts of data, AI can help identify patterns in the consumption of plastics, predict trends and make informed decisions to reduce the use of plastics and promote the Circular Economy.

Another obstacle is the lack of skilled labour with the necessary knowledge of AI and plastics technology. Finally, employee acceptance poses a challenge, as the use of AI changes work processes. Employees may first need to be trained in the use of AI technologies. AI in the plastics industry: an outlook Overall, the future of AI in the plastics industry looks promising.

There is great potential to significantly increase efficiency and sustainability. AI is expected to continue to optimise processes, from material selection to end-of-life processing, and promote innovative recycling methods. The develop-

ment of smarter, self-learning systems could improve the adaptability of production and contribute to the realisation of a fully circular economy. Despite challenges in terms of data, integration and skilled labour, the increasing focus on sustainability and technological advances is expected to drive the adoption and implementation of AI in the industry.Artificial

Intelligence in the Plastics Industry: Sustainability through Technology.

How Algorithms are supporting the Industry today Artificial intelligence is revolutionising modern industry.

Thanks to it, complex processes can be automated, efficiency increased and further innovations made possible. In the plastics industry, AI not only plays a decisive role in the optimisation of production processes and the development of new materials. It also enables more precise waste sorting and therefore better recycling – a win for the environment!

POLYMERS & RUBBER MATTERS | OCTOBER 2024 | 21

THINK OUTSIDE THE BOX

TECHNOLOGIES FOR PLASTIC PIPES PROCESSING

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Wonderfully versatile: Plastics shape the car of the future Interview with Alex Horisberger, Senior Specialist Product Design, BASF

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he versatility of plastic is one of its strongest characteristics, and it makes it particularly popular amongst designers. Once you have found the right plastic for a project, you have endless design possibilities. Plastic is also a favored material for BASF's design team: in collaboration with Citroën, the chemical company rethought the classic car with plastic as the central building block that made the implementation of the innovative concept possible in the first place.

Alex Horisberger: In many aspects, the concept car answers questions that are directed at the mobility of tomorrow: How can I simplify my commute? Can a vehicle save resources and be fun at the same time? How can it look good at the same time? The result is a particularly lightweight yet robust and durable automobile - without frills, unnecessary luxuries and well thought out down to the smallest detail.

What challenges arise in such a development? What requirements have to be met?

Horisberger: Durability, recyclability

and simplicity play a crucial role in the novel concept. At the same time, the aim was to make sustainability look good. And in terms of production technology, the simplification principle was also consistently implemented; for example, the driver and passenger doors are identical. During development and design, we worked closely with Citroën to select the right materials from BASF's broad portfolio.

To what extent can plastics help meet these challenges?

Horisberger: Plastics are incredibly versatile and can therefore contribute to the functionality and functional integration of many vehicle components. Our polyamides have also proven their longterm durability many times over under typical automotive conditions without aging or corrosion. Of course, the sustainability aspect is also crucial: BASF is developing plastics that enable both mechanical and chemical recycling to support the industry in its transition from a linear to a circular economy. In addition, these engineering plastics

can be made from renewable or recycled raw materials.

Horisberger: We are dealing here with the reversal of the normal approach to a product, because often the prevailing principle is 'form follows function'. But when we look at a car from a sustainability perspective, materials and manufacturing technologies have to come first. In this project, the boundaries were pushed further and further, whether by using materials in unusual ways or by fundamentally rethinking the design of a component.

Which plastics are used in the concept car and why exactly these?

Horisberger: To make Citroën's vision of reusability and simplicity a reality, BASF relied on the material of a single TPU product family for the interior, for example, thereby facilitating mechanical recycling at the end of the product life cycle.

Thanks to their versatility, our TPU grades enable different functions in the process. One visionary highlight of the concept, for example, was the production of a 3D-printed seat

made of TPU material that is both highly flexible and functional. The iconic storage compartment (Elastollan®) and the vehicle floor (Infinergy®) are made from the same product family. The exterior features lightweight yet robust plastic components that on the one hand reduce energy consumption while driving, but on the other hand leave design managers with all the design options they need. The hood, roof and pickup-like trunk made of Elastoflex® are strong enough to be used as ladders, roof tent bases or for transporting Christmas trees.

How do you assess future developments as far as the use of plastics in design objects is concerned?

Horisberger: In the numerous customer projects we carry out as BASF Creation Center, we see that the versatility of plastics, combined with the right sustainability concepts, offer designers endless possibilities to design clever products that really make consumers want to act sustainably. Just as oli impressively demonstrates: Modesty and sustainability can look good!

POLYMERS & RUBBER MATTERS | OCTOBER 2024 | 23

Breaking boundaries: Delivering gigantic injection molding machines across continents Interview with Anders Nybäck, Sales Director Technical Moulding, ENGEL AUSTRIA 8000 tons in weight, a good 30 meters long – how do you manage to ship such a gigantic injection moulding machine across the big pond? In an industry where logistics and size present special challenges, ENGEL has managed to master them with expertise and a cooperative approach.

In an interview with K-MAG, Anders Nybäck, an expert from ENGEL, sheds light on the successful delivery of two massive 8,000-ton injection molding machines from Austria to the United States. What is the significance of these machines, and how is the future outlook for injection molding machines with such high clamping forces?

Mr. Nybäck, ENGEL recently delivered two 8,000-ton injection moulding machines to the USA. How did that happen exactly? And how long did it take from order to handover?

Anders Nybäck: ENGEL received the order in November 2020 and the first machine could already be handed over in February 2022. Now, one year later, a second identical machine has been delivered.

What must be considered when supplying machines of this size?

Nybäck: Logistics is a special challenge. Before delivery, each

machine is completely assembled and tested at the ENGEL plant. Such large machines then have to be disassembled again for transport.

The weight of the individual components plays a major role in logistics planning. The mould fixing platens for these two 8000-ton machines, for example, were transported on barges on the Danube.

and more very large components are being produced by injection molding for which other processes were previously used or which were previously assembled from several individual components - for example, large containers and underground tanks, but also more and more large-area vehicle components such as structural components and lightweight body components or glazing. We see a lot of potential in the automotive sector in particular. Hyundai-Kia in Korea, for example, recently took delivery of a particularly large injection molding machine from us.

What challenges did you face and how did you overcome them?

Nybäck: ENGEL has a great deal of experience and expertise in building large-scale machines and also a global production network, which simplifies logistics, shortens time-to-market and makes the overall project more costeffective. ENGEL already has a long business relationship with Infiltrator. This was the deciding factor in this particular case. All previous projects for Infiltrator were completed by ENGEL on time, and costs were not exceeded either. Therefore, Infiltrator also placed the necessary trust in us for this particularly challenging project.

Nybäck: From the initial idea to completion, the project was a close team effort across company boundaries. Our long collaboration with Infiltrator, mutual trust, and not least the fact that everyone knows what is important to the other were key success factors here. This is the only way to deal with the risks that naturally come with the size of the machines, the degree of innovation and the immense investment volume. We are thrilled to see what we have achieved here together.

When we develop solutions together with our customers, we do everything we can to make them even more successful with innovative and forward-looking concepts.

What makes injection molding machines with such high clamping forces necessary?

Nybäck: Injection molding enables particularly resource-efficient processing of plastics and also a high degree of process integration and automation. As a result, more

24 | OCTOBER 2024 | POLYMERS & RUBBER MATTERS

Why did Infiltrator approach ENGEL specifically with its request?

What makes your machines special?

To what extent does ENGEL contribute to sustainability with these injection molding machines (e.g. in this specific case)?

Nybäck: The large machines make it possible to produce components that previously consisted of several individual parts and had to be assembled in a single process step and in one piece. This saves process steps and thus a lot of energy and raw material. Infiltrator also says that with the new machines they can manufacture the products even more cost-effectively and efficiently. Sustainability played a major role in the overall project. Infiltrator produces innovative water management products that have a high percentage of recycling. The company recycles more plastic than any other in North America.

How will the demand for injection molding machines with such high clamping forces develop in the future and how is ENGEL preparing for these developments?

Nybäck: We see an increasing need and an increasing demand. However, it is important to realize that injection moulding machines with clamping forces of over 5500 tons are a niche market and will remain that way. However, this niche is very interesting for ENGEL because we are one of the injection moulding machine manufacturers with the greatest experience and competence in the field of large machines. Not to forget: With our worldwide production network, we have the capacity to efficiently build and deliver such machines.

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Kiefel presents new SPEEDFORMER KTR 6.2 machine for higher output at the same footprint & quality KIEFEL GmbH, a market leader in the design and manufacture of polymer and natural fiber processing machines, automation and tools, has launched the new tilting machine SPEEDFORMER KTR 6.2 SPEED for the mass production of polymer cups and coffee capsules. This technology solution provides higher productivity and production versatility while offering 10% energy savings due to optimized heating.

which is a family-owned group of medium-sized enterprises active in machinery and plant engineering with around 2,900 employees at 18 locations worldwide.

KIEFEL GmbH | www.kiefel.com

Increased output thanks to optimized technology and design The new SPEEDFORMER KTR 6.2 is designed for large-scale production of high-end thermoformed polymer cups, offering up to 50% higher output at the same footprint & quality compared to other machine manufacturers.

“This increased output is possible thanks to its larger forming area combined with faster forming time due to an improved tooling cooling process.

Additionally, the filling time is drastically reduced owing to the optimized forming air system”, emphasizes Alexander Donabauer, Director Sales of the Polymer Packaging Division at Kiefel.

Stronger punching force and taller polymer cups The KTR 6.2 features a more powerful drive system at the Trim-in-place station, offering an impressive punching force of 900 kN. Therefore, this cutting-edge tilting machine can easily punch a wide variety of materials, including thicker films, such as PET, which usually require stronger punching forces. Furthermore, the machine technology is enhanced to produce higher cups up to 250 mm.

SPEEDFORMER KTR 6.2 SPEED for efficient thermoformed polymer cup production. © KIEFEL GmbH

New advanced stacking & automation solutions for faster production Additionally, customers can achieve even higher production speed with two innovative modules: the optimized and integrated SPEEDSTACKER for efficient and higher stacking, which can handle a greater number of products and a wider range of geometries, as well as the new downstream automation CUPPACKER for cup packaging, which can be optionally integrated into the KTR 6.2. They offer optimized product transfer that uses real-time monitoring to guarantee maximum speed and output and smooth machine movements.

“Moreover, the KTR 6.2 includes a new intuitive user interface, KMI 2.0, which facilitates thermoforming processes, supporting customers from a short training period and fast recipe optimization to efficient error handling and a targeted maintenance system”, adds Alexander Donabauer.

Variety of high-quality polymer cups manufactured in the SPEEDFORMER KTR 6.2 SPEED. © KIEFEL GmbH

About Kiefel Kiefel develops and produces high quality machines for processing plastics, recycled and bio-based materials as well as natural fibers. Kiefel's customers include well-known manufacturers from the medical engineering & pharmaceuticals, refrigerator, and packaging industries. With its own technology and material centers, the company offers turnkey solutions and provides support in partnership from product development through machines and tools to after-sales service.

Kiefel has a global presence thanks to our own sales and service teams in the USA, France, the Netherlands, China, India and Thailand, as well as our sales and service partners in more than 60 countries.

KIEFEL GmbH owns the Dutch thermoform toolmaker Kiefel Packaging BV, as well as the Austrian company KIEFEL Packaging GmbH, a supplier of tools and automation solutions. Kiefel and its subsidiaries employ around 900 staff. KIEFEL GmbH is a member of the Brückner group, based in Siegsdorf, 26 | OCTOBER 2024 | POLYMERS & RUBBER MATTERS

Cups and coffee capsules made of various polymers produced on the KTR Series. © KIEFEL GmbH

REVOLUTIONIZING FIBER OPTIC INFRASTRUCTURE: THE RISE OF MICRODUCT PIPES AND TECNOMATIC’S OUTPERFORMING DIE-HEAD AND LINE.

I

n the era of rapid technological advancement, where connectivity is king, the demand for highspeed internet has never been greater. With this surge in demand comes the need for robust and efficient infrastructure to support it.

Enter microduct pipes for optical fiber, a groundbreaking solution that is revolutionizing the telecommunications industry.

Microduct pipes are small, flexible conduits designed to house optical fibers, protecting them from environmental factors while facilitating easy installation and maintenance. Their compact size and flexibility make them ideal for various applications, from urban environments to rural areas, and even within buildings.

One of the key players in this burgeoning market is Tecnomatic, a company at the forefront of innovation in extrusion technology.

Tecnomatic's groundbreaking lines,

specifically engineered for microduct pipe production, have set new standards in terms of speed, efficiency, and quality.

Tecnomatic's die-head is its ability to maintain impeccable sizing results even at such high speeds. With minimal tolerance and ovality, the microduct pipes produced are of the highest quality, meeting the stringent standards of the telecommunications industry.

At the heart of Tecnomatic's innovation lies its die-head, meticulously designed to achieve unprecedented production speeds.

Capable of reaching up to 400 meters per minute for diameters of 7/3.5 and up to 200 meters per minute for diameters of 14/10, this die-head stands as a milestone in microduct pipe manufacturing.

Moreover, Tecnomatic's die-head is engineered for efficiency and flexibility, allowing for fast skin and colour changes with the adoption of special valves and multiple extruders. This feature not only enhances productivity but also enables manufacturers to meet the diverse needs of their customers with ease.

The secret behind Tecnomatic's remarkable speed and precision lies in its innovative geometries, precise line adjustments, and profound understanding of the production process. By optimizing these factors, Tecnomatic has been able to push the boundaries of what was once thought possible, achieving production speeds that were previously unimaginable. One of the most remarkable achievements of

The implications of Tecnomatic's innovative die-head extend far beyond the realm of microduct pipe production. By enabling faster, more efficient manufacturing processes, it paves the way for accelerated deployment of fiber optic networks worldwide. This, in turn, translates to improved connectivity, economic growth, and quality of life for millions of people around the globe.

As the demand for high-speed internet continues to rise, so too does the importance of robust and efficient infrastructure. With Tecnomatic's groundbreaking die-head leading the way, the future of fiber optic connectivity has never looked brighter.

POLYMERS & RUBBER MATTERS | OCTOBER 2024 | 27

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LyondellBasell helps to close the loop on Polypropylene by joining NEXTLOOPP initiative

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EXTLOOPP, launched in October 2020, aims at creating circular foodgrade recycled polypropylene (FGrPP) from post-consumer packaging.

LyondellBasell (NYSE: LYB), one of the largest plastic and chemical companies in the world, has recently joined the initiative that brings more than 40 major industry players together.

"To unlock the full value of plastics, critical gaps must be addressed so these valuable resources can be circulated back into the economy after use. The development of innovative, new solutions and the increase of recycling rates is key to addressing plastic waste and climate change," says Richard Roudeix, Senior Vice President Olefins & Polyolefins EMEAI at LyondellBasell.

"In the area of post-consumer polypropylene for food packaging, we are eager to join and support the research of the NEXTLOOPP project, together with other industry players, to help find new solutions." Polypropylene is the most widely used plastic in food packaging. NEXTLOOPP is able to close

the loop on polypropylene (PP) by using a combination of cutting-edge technologies, developed by Nextek Ltd. It does this by separating foodgrade PP from the rest, and by decontaminating the polymer to ensure compliance with food-grade standards in the UK, EU and the U.S. Following outstanding results of its innovative tracer-based sorting trials, Nextek Ltd recently started production trials of food-grade compliant recycled PP, making over 60 different products from NEXTLOOPP's four grades of PPristine food compliant and INRT rPP grade resins.

Professor Edward Kosior, founder and CEO of Nextek Ltd and NEXTLOOPP said, "We are delighted to welcome LyondellBasell to our project. As we continue to build momentum, LyondellBasell’s expertise on delivering technologies that advance solutions to our world’s biggest challenges will be key."

Solvay extends its sustainable polymer offering for smart devices and wearables

S

olvay just launched the Kalix® 10000 series, an ideal structural material for precision electronics components used in smart devices, to complement its Kalix® product line. The newest HPPA-based material is set to take both performance and sustainability to the next level.

The Kalix® 10000 series, a partially bio-based material made with renewable feedstock from non-food competing sources, is produced with 100 percent renewable electricity. Available with a wide range of recycled content alternatives for diverse customer needs, it also has a lower global warming potential (GWP) than traditional polyamides. Additionally, it offers higher heat resistance, stain resistance, and lowest moisture absorption in the Kalix® families, making it suitable for use in electronic applications with more demanding customer requirements.

"Our Kalix® portfolio has seen high demand, as it delivers the highest elongation and weld line strength of all HPPA, as well as great stiffness and chemical resistance. It also shows low moisture absorption, which makes it an ideal structural material for precision electronics components," said 38 | OCTOBER 2024 | POLYMERS & RUBBER MATTERS

Andrew Lau, Senior Executive Vice President of Solvay Materials. "The Kalix®10000 series further strengthens the Kalix® family as it not only exceeds the performance demands of structural and cosmetic frames for smartphones, but it also is a more sustainable solution that meets evolving customer needs."

The average lifespan of consumer devices, and the parts that go into them, have been rapidly decreasing. Vast amounts of waste will continue to be generated and cause sustainability challenges. Solvay has developed advanced technologies to help manufacturers close the loop between product design and production execution on the factory floor. With a multitude of sustainable materials solutions that address various market needs, the company is working to put our society on a fast track towards more circular solutions.

Sustainable plastic packaging: AI supports design and production Interview with Mauritius Schmitz, Scientific Director, Institute for Plastics Processing (IKV) in Industry and Craft at RWTH Aachen University

P

lastic packaging made from recycled material? Yes, but please as high quality as possible – and recyclable! This poses great challenges for manufacturers, because the use of recycled materials still often leads to downcycling. One key to more sustainable plastic packaging lies in digitalisation. This is also where the KIOptiPack project comes in.

In an interview, Mauritius Schmitz talks about the requirements for plastic packaging, the role that design plays in the sustainability of packaging and the extent to which artificial intelligence can support this.

To make plastic packaging more sustainable, the entire value chain must be considered. The KIOptiPack innovation lab deals with the beginning of the value chain - design and production. What role does design already play in sustainability?

Mauritius Schmitz: Product design plays a central role in the sustainability of products. It defines the choice and consumption of materials and thus the types and quantities of plastic introduced into the cycle. It also influences functionality and suitability for (packaging) use, manufacturability and production efficiency.

Furthermore, product design can facilitate or complicate the sorting, separation and reprocessing processes – which in turn determine the quality of the resulting recyclates.

Schmitz: Even with sustainable

packaging design, the same, or at least comparable, expectations and criteria must be fulfilled for the product as for products made of virgin material.

This is about product functionalities, such as barrier properties, purity and mechanical stability, and about subjective requirements from the consumer's point of view, such as appearance, smell and safety. But also the processability of the chosen material in the production process plays a decisive role for a functioning product design, by this I mean, for example, the thermal or flow properties of the plastic.

AI can be used to take these complex and diverse influences into account and make them optimisable. By using AI, these influences can be made quantifiable and packaging designers can get a better idea of how their designs affect the different requirements and how they can optimise them to create more sustainable packaging.

Graphic: Illustration of the support provided by AI throughout the entire plastic packaging cycle; Copyright: Institute for Plastics Processing (IKV) in Industry and Craft at RWTH Aachen University Copyright: Institute for Plastics Processing (IKV) in Industry and Craft at RWTH Aachen University How can AI make production more sustainable?

Schmitz: To improve the quality of plastic packaging, AI is used in different production phases. AI is already used at the material receiving stage to detect material fluctuations and adjust the processing accordingly. During the processing stages, neural networks are used to

generate and optimise process models. In this way, correlations between material characteristics, process settings and quality can be recognised and used for correct process adjustment. In the KIOptiPack project, the processing methods compounding, flat film and blown film extrusion, injection moulding and thermoforming are specifically considered.

Graphic: Goals of KIOptiPack; Copyright: Institute for Plastics Processing (IKV) in Industry and Craft at RWTH Aachen University Copyright: Institute for Plastics Processing (IKV) in Industry and Craft at RWTH Aachen University Why is cooperation with industry – i.e. companies like Brückner, Reifenhäuser or Pöppelmann – important?

Schmitz: Cooperation with industry is of great importance and depends in its way on the respective industry.

However, an important aspect that has not been sufficiently considered so far is the consideration of the entire value chain. In order to achieve optimal sustainability, changes have to be made at various points in the value chain, which may not be initiated and implemented out of their own motivation. For example, the responsibility for more sustainable plastic packaging could be shifted to the collection and reprocessing process alone, but this would certainly not be the most effective and sustainable approach.

Instead, it makes more sense to develop incentives and business models that enable global change and load-sharing along the entire value chain.

To achieve this goal, it is essential to understand the hurdles and

potentials for each participant.

Through the AI Application Hub, which networks project partners from established machine manufacturers to technology start-ups, as well as from research institutes to food manufacturers and distributors, the possibility of a direct exchange along the entire value chain is created. Only in this way can we achieve a common understanding of the potentials of more sustainable packaging production.

What will the plastic packaging of the future look like?

Schmitz: It is difficult to predict what packaging will look like, because we will also be able to develop and produce sustainable plastic packaging in great variety in the future.

These will be individually tailored to the specific application, so that they fulfil minimal material consumption and at the same time reliable suitability for the application. At the same time, however, this packaging will have to be returned to the cycle with the minimum possible losses.

What can already be predicted with great certainty, however, is that the packaging of the future will contain a maximum proportion of recyclate. It will preferably contain only one type of polymer and be easier to handle when sorting and separating.

In order to improve and simplify the sorting processes, digital – and at best global – product or material passports, which are currently being developed through various initiatives, will play a decisive role.

And in this area, we will not make progress without digitalisation and artificial intelligence methods.

POLYMERS & RUBBER MATTERS | OCTOBER 2024 | 39

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Plastics of the future will live many past lives, thanks to chemical recycling

O

ne day in the not-toodistant future, the plastics in our satellites, cars and electronics may all be living their second, 25th or 250th lives New research from the Colorado University Boulder, published in Nature Chemistry, details how a class of durable plastics widely used in the aerospace and microelectronics industries can be chemically broken down into their most basic building blocks and then formed once again into the same material.

It's a major step in the development of repairable and fully recyclable network polymers, a particularly challenging material to recycle, as it is designed to hold its shape and integrity in extreme heat and other harsh conditions. The study documents how this type of plastic can be perpetually broken down and remade, without sacrificing its desired physical properties.

other plastic materials could lead to similar discoveries of how to fully break down and rebuild their chemical bonds, enabling the circular production of more plastic materials in our daily lives. In the mid20th century, plastics were ubiquitously adopted in almost every industry and part of life as they are extremely convenient, functional and cheap. But half a century later, after exponential demand and production, plastics pose a major problem to the health of the planet and to people. The production of plastics requires large amounts of oil and the burning of fossil fuels.

Disposable plastics create hundreds of millions of tons of waste every year, which ends up in landfills, oceans and even in our bodies, in the form of microplastics.

"We are thinking outside the box, about different ways of breaking chemical bonds," said Wei Zhang, lead author of the study and chair of the chemistry department. "Our chemical methods can help create new technologies and new materials, as well as be utilized to help solve the existing plastic materials crisis."

Recycling, therefore, is key to reducing plastic pollution and fossil fuel emissions this century.

Conventional recycling methods mechanically break down polymers into powders, burn them or use bacterial enzymes to dissolve them.

The goal is to end up with smaller pieces that can be used for something else. Think shoes made from recycled rubber tires or clothing made from recycled plastic water bottles. It's not the same material anymore, but it doesn’t end up in a landfill or the ocean.

Their results also suggest that revisiting the chemical structures of

But what if you could rebuild a new item from the same material? What if

50 | OCTOBER 2024 | POLYMERS & RUBBER MATTERS

recycling didn't just offer a second life to plastics, but a repeat experience?

That's exactly what Zhang and his colleagues have accomplished: They reversed a chemical method and discovered they can both break and form new chemical bonds in a particularly high-performance polymer. "This chemistry can also be dynamic, can be reversible, and that bond can be reformed," said Zhang. "We are thinking about a different way to form the same backbone, just from different starting points." They do this by breaking the polymer –"poly" meaning "many"– back into singular monomers, its molecules, a concept of reversible or dynamic chemistry. What's especially novel about this latest method is that it has not only created a new class of polymer material that, like Legos, are easy to build, break apart and rebuild over and over, but the method can be applied to existing, especially hardto-recycle polymers.

These new chemical methods are also ready for commercialization and can plug and play with current industrial production."It can really benefit future design and development of plastics to not only create new polymers, but it's also very important to know how to convert, upcycle and recycle older polymers," said Zhang. "By using our new approach, we can prepare many new materials—some of which could have similar properties to the plastics in our daily life."

This advance in the closed-loop recycling of plastics is inspired by the natural world, as plants, animals and human beings alike are currently part of a planetary-level, circular system of recycling, said Zhang. "Why can't we make our materials the same way?"

Reducing Carbon Emissions in the Economy

H

ow can the economy be restructured to lower carbon emissions? What steps towards decarbonisation have nations already taken and how successful have they been? These are the questions to be addressed in a research project whose participants include scientists from the Institute for Political Science at Heidelberg University. Prof. Dr Jale Tosun will head up the work in Heidelberg which will start at the beginning of 2021. The work is part of a project based at the University of East Anglia (Great Britain), which the European Research Council

(ERC) is funding with an ERC Advanced Grant for leading researchers. A total of nearly 2.4 million euros has been granted for the project. Approximately 530,000 euros is earmarked for the research in Heidelberg.

In the “Deep Decarbonisation: The Democratic Challenge of Navigating Governance Traps” (DeepDCarb) project, coordinated by Prof. Dr Andrew Jordan of the University of East Anglia, the researchers first want to gain a fundamental understanding of climate policy action throughout the world. Datasets from the past 30

years that depict the activities of 41 countries with different levels of economic development will be used as a basis.

The researchers will then look more closely at the processes that have already brought about the passage of climate policy laws and enactments in the past. “Further on, we will link political science research with approaches from the behavioural sciences. The central question is how should decisionmaking situations be set up to achieve long-term goals, like reducing global warming to 1.5

degrees,” explains Prof. Tosun. The researchers in Heidelberg will be creating empirical models to measure climate policy action and thus explain how climate policy is developed. “In past projects, we already developed approaches to measure legislative activities in this area for a large number of nations and over long periods of observation,” adds Prof. Tosun. “With our research activities in the DeepDCarb project, we plan to continue this work and facilitate insights that can be implemented in practice and thus benefit policy and public administration.”

POLYMERS & RUBBER MATTERS | OCTOBER 2024 | 51

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Find out more www.staubli.com

FROM PLASTICS. TO THE FUTURE.

BRINGING OUT THE BEST. FOR OUR WORLD. CIRCULAR ECONOMY & RECYCLING SOLUTIONS KraussMaffei helps you gain the purest re­ cyclates in a „like new“ quality that seemed unimaginable a few years ago. We imple­ ment your formulations in a way that costs little in terms of money, energy and CO2 emissions. Our groundbreaking technology in compounding and recycling gives you the critical edge in the competition for sustain­ ability – for your company‘s figures and our children‘s future.

DISCOVER MORE ABOUT OUR INDUSTRIES www.kraussmaffei.com