Smart, Sustainable, and Responsible Extrusion Technologies Take the Spotlight at K 2025
As the world plastics industry looks ahead to one of the most significant trade shows in the world—K 2025 in Düsseldorf—battenfeld-cincinnati stands out as a leader, emphasizing its dedication to ecological responsibility, technological innovation, and optimized production. With its thematic call to action “Think Green, Act Smart, Extrude Sustainably,” the company is not just attending—it’s leading the charge. As a global market leader for extrusion machines, battenfeld-cincinnati will illustrate how the values of sustainability, digitalisation, and industrial performance are not only compatible but also reinforcing each other. This year’s K 2025 is more than an exhibition—it’s a declaration that the strength of plastics is being re-defined for a more sustainable future.
The plastics market is being revolutionized by customers and regulators alike, who are demanding smarter operations, improved resource efficiency, and closed-loop solutions. Plastics processors today have to function in a fast-pressure market where innovation has to be a solution for live problems: energy consumption has to decline, recycled products have to be economical at volume, automation has to be wise, and product has to remain competitively priced. To meet these increasing needs, battenfeld-cincinnati is launching an extensive range of innovative extrusion technologies, converting vision into real-world, sustainable engineering.
Center of attention at the firm’s stand is the latest BC 120-40 DVT single-screw extruder, an innovation that sets a first by being the first of its kind to come with Dual Vent Technology. This technology advancement brings with it a two-stage melt degassing system tailored to deal with tough and dirty recycled materials without compromising on better product quality. This degassing process eliminates volatiles and water more effectively, with the capability to accept high levels of recyclate content in the feedstock without compromising the integrity of the end product. Maybe most impressive is that all this is done with lower energy consumption, lesser thermal loads, and less waste—characteristics of a system fully in line with sustainable objectives.
This new extruder wasn’t created in isolation. It’s the product of global collaboration across battenfeld-cincinnati’s R&D and engineering divisions. Its development reflects a core philosophy of leveraging internal synergies, integrating proprietary software, thermal management systems, and mechanical innovations into a unified machine platform. More than just a new piece of hardware, the BC 120-40 DVT serves as proof of concept that future-ready extrusion systems can be high-performing and environmentally sound at the same time.
“We are demonstrating that green, smart, and responsible are specific development guidelines for us. The combination of economic efficiency, high flexibility, and active sustainability makes battenfeld-cincinnati a reliable partner for future challenges. We look forward to discussing these topics in person with our customers at K and developing them further.”
In pipe extrusion, the company also debuts another significant innovation: Intelligent Operating Adjustment (IOA). This automated centering system of ball-joints significantly decreases operator intervention in pipe production, optimizing the use of materials and enhancing accuracy. IOA allows the extrusion line to automatically maintain optimal positioning, with the result that the pipe is always centered—something usually requiring operator expertise and constant adjustment. With reduced material required for the corrections and less rejects, the system increases productivity as well as sustainability. It is also a classic case of Industry 4.0 in practice—autonomous, smart, and highly integrated into the digital world of manufacturing.
In addition to this, battenfeld-cincinnati introduces a new degree of flexibility with its piggyback coextrusion solution, a space-saving line integrating the twinEX 78 and conEX NG 65 extruders. This innovative technology enables the simultaneous processing of virgin PVC, recyclates, and special compounds with high output and consistent quality. The design is suited to manufacturers that face varying production requirements, allowing them to change product types rapidly or blend materials for new products. The NG series extruders also cement their green credentials through the use of low-energy screw design, accurate thermal zoning, and the capability to process heat-sensitive materials—all with the ability to produce scalable outputs adequate for commercial-level manufacturing.
For producers of sheets and films, the upgraded multiTOUCH-X roll stack with Axis-Crossing Technology is making waves. Designed for extremely thin films—such as polypropylene below 200 microns or PET below 150 microns—the system eliminates the need for vacuum boxes. This not only reduces energy requirements but also shortens startup times and improves safety. The result is high-speed production with minimal scrap and outstanding film quality. In terms of innovation, it’s a leap that supports lightweight packaging and recyclable film applications, which are gaining traction as both consumers and regulators push for reduced environmental impact.
To complement this, the new solEX NG 105 extruder is being launched, offering throughput levels of up to 2,100 kilograms per hour while maintaining lower melt temperatures. What sets this extruder apart is its closed-loop cooling circuit, developed entirely in-house. Unlike conventional systems, this cooling loop operates independently of the main water supply, offering corrosion protection, thermal stability, and extended longevity of key extruder components. For manufacturers, this translates to better machine uptime, fewer maintenance disruptions, and significantly lower operational costs.
In downstream processing, the company is showcasing its next-generation pullStream B63-1000 WS belt haul-off, designed with World Solution Design principles. Its ergonomic structure prioritizes user-friendly operation, offering tool-free maintenance access, integrated belt alignment, and a 10-inch touchscreen interface for intuitive control. Even at high line speeds of up to 300 meters per minute, the system ensures consistent pipe quality and seamless integration with other line components. It exemplifies how operator comfort, digital control, and production efficiency can coexist to create superior manufacturing environments.
One of the more forward-looking tools on display is the Spider NG tooling system, a modular setup tailored for the evolving demands of PVC pipe manufacturing. Its design allows quick adaptation to changing requirements, enabling manufacturers to shift product formats, layer configurations, or input material compositions without needing entirely new die heads. This level of adaptability is especially vital in today’s regulatory climate, where producers must be ready to meet new environmental standards and shift toward higher use of recyclates or bio-based compounds.
That vision isn’t theoretical—it’s supported by a wide portfolio of machines and services designed for real-world implementation. battenfeld-cincinnati’s full range includes solutions for pipe, profile, thermoforming sheet, and packaging film extrusion. Their platforms—like solEX NG, conEX NG, uniEX, and others—are supported by process control innovations such as BCtouch UX, a unified control interface that brings user-friendly navigation, predictive maintenance, and OPC UA-ready data integration into every machine.
In fact, digitalization is a key enabler of their sustainability goals. With BCtouch UX, operators receive real-time feedback, automated diagnostics, and intelligent system suggestions—reducing downtime, material waste, and human error. Its connectivity to manufacturing execution systems (MES) and enterprise platforms also supports traceability, regulatory compliance, and lean manufacturing principles.
Globally, battenfeld-cincinnati serves customers with a distributed network of service centers and manufacturing sites. From Europe to North America to Asia, their regional hubs provide commissioning, remote diagnostics, preventive maintenance, and training tailored to local market needs. Their “World Solution” standard ensures that equipment specifications meet the highest international benchmarks while allowing for customization to meet local processing norms or climate conditions.
What truly distinguishes battenfeld-cincinnati at K 2025 is their ability to turn abstract ideals—like circular economy, energy efficiency, and digitalization—into tangible, measurable, and profitable realities for processors. From their dual-vent extruders that make high-recyclate content feasible to automated centering systems that reduce waste, their portfolio is not just innovative but strategic. For converters, brand owners, and compounders alike, their systems offer a roadmap to future-proof manufacturing.
As the countdown to K 2025 continues, battenfeld-cincinnati is positioning itself not only as a provider of cutting-edge machinery but as a key architect of the plastics industry’s next era. It is a future defined not just by performance, but by purpose. One where plastics—so long seen as a sustainability challenge—are being reimagined as part of the solution. A future where thinking green, acting smart, and extruding sustainably are not marketing phrases but operational realities.
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