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Smart Measurement Elevates Plastic Processing Efficiency at K 2025

Smart Measurement Elevates Plastic Processing Efficiency at K 2025

From October 8 to 15, 2025, SIKORA AG will showcase cutting-edge technology for measuring, control, inspection, and sorting at the international trade show K 2025 in Düsseldorf. With an emphasis on product quality, material efficiency, sustainability, and economical manufacturing, the systems on display raise the bar for quality control in the tube, pipe, hose, and plastics industries.

Photo Credit: Messe Düsseldorf

Plastic processing and manufacturing technologies must progress to meet the growing demands of infrastructure, urbanization, electromobility, and recycling. SIKORA tackles these issues with creative solutions that guarantee superior quality and production efficiency, such as in the production of water, gas, or wastewater pipes, where supply security depends on quality. Because purity dictates the final product’s sustainable use and recyclability, plastic pellet manufacturers also gain from this.

Global markets in transition: Demand for intelligent measuring technology is growing

The global demand for measuring technology in the plastics and pipe industry is rising, driven by infrastructure modernization in countries like China and other emerging markets, as well as growing demand for high-quality pipe systems in the course of urbanization. In Europe and North America, the focus is shifting towards energy efficiency and the renovation of existing supply networks. Electromobility also presents new production challenges – for example, in the manufacturing of high-quality battery cooling lines – which SIKORA’s measuring technology reliably addresses.

Maximum purity for high performance
In the plastics industry, high-performance applications are becoming more and more significant. Cross-linked polyethylene (XLPE) and fluoropolymers, which are nevertheless used in the manufacturing of cables despite regulatory obstacles, particularly in the pharmaceutical and automotive sectors, are subject to increasing purity requirements. The best material quality is also required for optical polymers like polycarbonate, which are gradually taking the place of glass in displays. When sorted with the highest care, polypropylene (PP) is becoming a more affordable and recyclable substitute for XLPE.

Inspection and sorting of plastic pellets with the PURITY SCANNER ADVANCED.

Live at the trade fair: Intelligent inspection and sorting solutions

At the trade fair, they will showcase the PURITY SCANNER ADVANCED, a powerful system that inspects plastic pellets in real-time using X-ray and optical technologies and sorts them with high precision. This is complemented by the PURITY CONCEPT V inspection and analysis system. Ideal for repeatable laboratory applications, it detects black and colored contaminants as small as 50 µm as well as discolorations. Under the motto “Human vs. Machine”, they invites visitors to bring small quantities of pellets or sample plates – and put their materials to the test. Participation is free and offers a great opportunity to experience the system’s precision, speed, and user-friendliness firsthand – and maybe even make a surprising discovery. Best of all: if no contamination is detected, participants will receive a small surprise. If contaminants are found, the visitor will receive a detailed inspection report providing valuable insights into material quality.

New standards in tube, pipe and hose extrusion

Artificial intelligence and data-based analyses play an important role in measuring technology and are already an integral part of SIKORA’s product development and the basis for further progress in the field of automated and autonomous quality control.

Another trade fair highlight is the new X-RAY 6000 PRO C-PIPE, a measuring system for precise detection of layer transitions in the production of double-wall corrugated tubes and pipes (DWC). It combines proven X-ray technology with AI-powered software that delivers reliable data on wall thickness and eccentricity, especially during the critical start-up phase of extrusion. This enables fast and efficient centering and significantly reduces start-up scrap. Artificial intelligence and data-driven analysis play a key role – already today, they are an integral part of their product development and a foundation for further progress in automated and autonomous quality control.

Also pioneering is the CENTERWAVE 6000, which uses radar technology to measure diameter, centricity, wall thickness, inner profile, and ovality of plastic pipes non-contact and across the entire circumference. The integrated “Dynamic Shrinkage Prediction” function allows for precise forecasting of the final pipe dimensions already after the first vacuum tank – a crucial advantage for early process optimization.

Innovations for sustainable production of tomorrow

At the heart of SIKORA’s trade fair presentation is the forward-looking vision: “Innovative Solutions for a Sustainable Future.” The goal is not only to advance technological innovations but to align them with economic benefits and ecological responsibility.

As a global provider of precise quality control in the production of tubes, pipes, hoses, and plastics, they contribute not only to product quality but also to resource conservation and climate protection. Through the targeted use of high-precision measuring and control technology, material use in production is optimized, significantly reducing the consumption of valuable raw materials. Their devices worldwide enable savings of around 3.6 million tons of plastic per year – equivalent to avoiding approximately 11 million tons of CO₂. This calculation is based on the assumption that producing one ton of plastic – such as HDPE, PE, or PP – generates an average of around 3 tons of CO₂ emissions. A prime example of this efficiency is the use of the CENTERWAVE 6000 for non-contact wall thickness measurement of pipes, which can reduce material usage by up to 8%. To put that into perspective: annually, the globally installed CENTERWAVE 6000 systems avoid as much CO₂ as several hundred million trees could absorb. This impressively demonstrates how technological innovation directly leads to greater sustainability in manufacturing.

SIKORA at K 2025: A clear signal for quality, efficiency, and future readiness

With its presence at the trade fair, SIKORA underscores its ambition to be a pioneer in intelligent, sustainable measuring technology solutions for the plastics industry. The presented systems address the industry’s current challenges and enable both economically and ecologically optimized production.

www.sikora.net

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K 2025 Showcases Smart Silicone Elastomers for Industrial and Consumer Use

K 2025 Showcases Smart Silicone Elastomers for Industrial and Consumer Use

Photo Credit: Messe Düsseldorf

At a press conference hosted by Messe Düsseldorf, WACKER presented its first product highlights for K 2025, the 23rd International Trade Fair for Plastics and Rubber coming up in October. In Hall 6 at Booth A10 – covering an area of 360 square meters and sporting WACKER’s new booth design –, the Group will be showcasing innovations in the areas of grid expansion, e-mobility, sensors and lifestyle applications.

WACKER will also display a new booth design at the trade fair. The portfolio will focus on new silicone products for energy, e-mobility, digitalization and sustainability. Highlights are ceramifying silicone rubber for e-mobility and electroactive silicone laminates for sensors, among others. Live-production of mouthpieces for air up water bottles with resource-saving silicone elastomers will take place during K 2025.

For the economical manufacture of hollow-core insulators, addition-curing solid silicone rubber is the main emphasis in the field of grid expansion. Additionally, a silicone solution for busbars is celebrating its debut in the field of electromobility. In the case of a fire, it ceramifies, preventing short circuits in electric automobiles‘ traction batteries.

Martin Bortenschlager, Director Engineering Silicones EMEA & LATAM, Photo Credit: Messe Düsseldorf
“Silicones are true all-rounders. In addition to being easy to process, extremely robust and versatile, they have very good mechanical properties. For this reason, they are increasingly being used for applications that place high demands on the materials required. This is what makes technical innovations in important industries possible in the first place, for example in electromobility, medical technology or digitalization,”

Another highlight is silicone laminates, which they recently began producing on a commercial scale. They are electroactive and can, for example, be used as sensors in the field of digitalization. There is also news on the sustainability front. For example, a novel product from the ELASTOSIL eco series. These silicones are produced using plant-based methanol and are therefore particularly resource-efficient. The product is hyperpure and requires no post-curing, thus making it suitable for use in lifestyle products and beverage bottles. During the trade fair, WACKER will be producing mouthpieces for air up water bottles with the new liquid silicone rubber (daily during the trade show from 9:30 am to 6 pm).

POWERSIL 1900 A/B, WACKER’s new high-consistency silicone rubber, facilitates the low-cost, high precision production of composite insulators via spiral extrusion processes.

Bortenschlager, an expert in silicones, cited the use of silicone products in energy transmission as an example. According to estimates by the European Commission, the refurbishment and expansion of energy networks in Europe will require investments of over 580 million euros. “As an insulation material, silicone plays an important and sustainable role in the safe operation of the energy grid. They insulate well, are resistant to both weathering and UV radiation and, unlike porcelain and glass insulators, do not normally need to be cleaned. They are therefore used in practically all areas of energy and transmission technology, especially in outdoor applications. “The demand here is immense and holds a huge market potential for us,” said Bortenschlager.

POWERSIL 1900 A/B

POWERSIL 1900 A/B is a new high-consistency silicone rubber for the production of hollow-core insulators. The product is supplied as a 2K system and is suitable for manufacturing processes that involve spiral extrusion. In contrast to other production methods, this makes the manufacturing of even large-scale insulators with variable diameters easier and more cost-effective. Thanks to their comparatively low weight, hollow-core insulators are much easier to install than rod insulators with a solid core. Weight savings may add up to 80 percent.

Interior view of a traction battery in an electric vehicle. The enlarged section shows the busbar (orange) insulated with ELASTOSIL R 531/60. It is bent and fit into the battery architecture after sheathing. Thanks to its high elasticity and notch impact strength, the silicone can easily cope with this molding and bending process.

ELASTOSIL R 531/60

Busbars are basically aluminum or copper rails that distribute the current between the battery cells and modules. As nominal battery voltages in electric vehicles are already in the range of 300 V to 900 V, the reliable insulation of busbars is a must. At K 2025, WACKER presents a new product that reliably insulates such components. ELASTOSIL R 531/60 makes the sheathing of busbars cost-effective. In the event of fire, the product ceramifies and forms an electrically insulating protective layer that reliably prevents short circuits. ELASTOSIL R 531/60 thus plays a vital role in passenger and fire safety of electric vehicles.

NEXIPAL Sense

Silicone laminates take the production of flexible printed electronics to the next level. NEXIPAL Sense laminates consist of highly stretchable silicone elastomers and electrically conductive silicone films that jointly work as a flexible and stretch-able capacitor. Pressure or flex movements change the electrical capacitance of the component. Different voltage states thus provide precise sensor signals for applications in medical technology, robotics and sports. At the Group’s production site near Burghausen, serial production of sensor laminates has started. WACKER will be presenting itself for the first time ever at this year’s K 2025 trade fair as a manufacturer of prefabricated components that are produced using a specially developed and fully automated roll-to-roll manufacturing process. This will position the company as the world’s first supplier of customized flexible sensor laminates on an industrial production scale.

At K 2025, WACKER will demonstrate live how ELASTOSIL eco LR 5003 is used to manufacture the mouthpiece of air up’s innovative water bottles

ELASTOSILeco LR 5003

In its sustainability zone, WACKER will present its new “eco” grade ELASTOSIL eco LR 5003. The non-postcure liquid silicone rubber is particularly suitable for the large-scale manufacture of products in the food industry and other sensitive areas. As far as their volatiles content is concerned, molded parts made from such silicones comply with the limits stipulated by the German Federal Institute for Risk Assessment (BfR) even without postcuring. They also meet the requirements of the U.S. Food and Drug Administration (FDA) for food-contact products. As a result, production of life-style products, drinking straws, baking tins, dough scrapers and other items is made very efficient. WACKER will use ELASTOSIL LR 5003 to injection mold mouthpieces for trendy water bottles designed by the company air up during the K show, using equipment by the courtesy of ARBURG and RICO Elastomere Projecting (live-demo daily from 9:30 am until 6:00 pm).

www.wacker.com/

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No Emissions, No Compromise: Bike Backpack Redefines Sustainability at K 2025

No Emissions, No Compromise: Bike Backpack Redefines Sustainability at K 2025

VAUDE, the outdoor apparel and equipment brand at the forefront of sustainable outdoor fashion and technology, introduces its groundbreaking partnership with BASF in creating the climate-friendly new TRAILCONTROL ZERO 20+ bike backpack. In its strategic integration of environmental responsibility and cutting-edge engineering, VAUDE uses BASF’s pioneering Ultramid ZeroPCF—a polyamide (PA) 6 with a zero Product Carbon Footprint (PCF)—to produce this next-generation bike backpack.

Photo Credit: Messe Düsseldorf

Ultramid ZeroPCF is not only a standard polyamide, but the very embodiment of carbon-neutral polymer science. It derives its zero-carbon status through a complete lifecycle strategy for sustainable production, wherein production runs on renewable electricity from the Hollandse Kust Zuid offshore wind farm, and biomethane and bio-based raw materials from used cooking oil displace fossil-based materials. This approach follows ISCC+ standards and is based on a certified mass balance system. The outcome is a material that has all the mechanical and visual characteristics of conventional polyamide 6 but far surpasses it in terms of environmental sustainability.

“Thanks to all these measures and the benefits we derive from the efficient production methods of our BASF Verbund, we are reducing the CO2 footprint of the polyamide to zero,” states Marcel Schmitt, Global Strategic Marketing, Polyamide 6 at BASF. The Verbund concept—BASF’s unique integrated production system—enhances resource efficiency by allowing by-products of one process to serve as raw materials in another, further minimizing waste and emissions.

This partnership between BASF and VAUDE not only represents a technological breakthrough but also illustrates the actionable steps companies can take toward climate neutrality. “With this flagship project, we want to stimulate discussions about how materials with a carbon footprint of zero can contribute to climate neutrality,” adds René Bethmann, Senior Material Innovation Manager at VAUDE. The brand has long been committed to environmentally responsible innovation and this collaboration reinforces that legacy.

The announcement follows BASF’s strategic October 2024 expansion of its polyamide portfolio to include Ultramid LowPCF and Ultramid ZeroPCF. These materials are a part of BASF Monomers division’s wider initiative to offer circular or PCF-reduced versions of all major product lines. This sustainable transition is integral to BASF’s long-term strategy for achieving net-zero CO2 emissions by 2050, aligning with global climate goals and industry expectations.

The VAUDE backpack will play a main role at the K 2025 International Trade Fair for Plastics and Rubber, scheduled from October 8 to 15, 2025, at Messe Düsseldorf. Under this event, BASF will highlight its “Choose to Reduce” strategy—showing customers and partners in industry how making the right material choice can reduce carbon emissions considerably without sacrificing on performance or product quality. The booth will feature BASF’s complete Ultramid portfolio, which now encompasses a series of climate-friendly polyamides for various applications in textiles, consumer products, automotive, and sports equipment.

This debut at K 2025 signifies a turning point for both companies—and, indeed, for the wider plastics and outdoor equipment industries—as they show that sustainability and high-performance materials need not, but should, go hand in hand. By embracing innovation, openness, and cooperation, the future is being rewritten—one carbon-neutral product at a time.

www.vaude.com

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K-Preview 2025 Unveils Plastics Innovations in Circular Design and Automation

K-Preview 2025 Unveils Plastics Innovations in Circular Design and Automation

At a time when plastic is coming under increasing scrutiny around the world—fueled by increasing awareness, consumer demand, and rising evidence of environmental damage—Reifenhäuser took a bold and timely move at K‑Preview 2025. Rather than simply demoing a slate of machines, the leader in extrusion technology presented a visionary case: converting plastics to a circular, high-performance, efficient material. Reifenhäuser’s presentation went beyond typical trade-show fare, providing a template for environmentally conscious yet commercially real packaging production.

Leading the spotlight was the revolutionary Machine Direction Orientation (MDO) technology, epitomized by the EVO Ultra Stretch module integrated directly into the haul-off section of blown film lines. This positioning allows the film to be stretched immediately from the initial heating, improving process stability and enabling the production of ultra-thin polyethylene (PE) films as thin as 18 µm, yet matching or even exceeding the performance of traditional 25 µm variants.

Marcel Perrevort, CSO of the Reifenhäuser Group, Photo Credit: Messe Düsseldorf
Marcel Perrevort, CSO of the Reifenhäuser Group, explains: “We entered the cast MDO market at an early stage, which means that, in addition to the hardware, we have a firm knowledge of the process. Together with partners,
we develop high-performance end products such as Cast All-PE stand-up pouches. As a line manufacturer, we always pursue one goal: to develop2/4 technology for recyclable films that are both functional and economical to
produce. We will be showcasing the successful results at K 2025”.

The implications are significant: a 25 percent reduction in raw material use, directly translating into lower carbon emissions and raw material costs. These films also maintain high mechanical robustness—with moduli of elasticity exceeding 1,400 MPa in machine direction and 1,100 MPa in transverse direction—and optical clarity with haze values below 5%, outperforming conventional benchmarks of 6–7%.

Crucially, the EVO Ultra Stretch maintains EVOH barrier content under 5%, ensuring compatibility with mono-material PE recycling standards. This means that while delivering high barrier functionality necessary for food and medical packaging applications, the entire film structure remains fully recyclable—a rare combination of performance and sustainability. Equally compelling were the real-world demonstrations: the 18 µm films were printed at speeds of up to 500 m/min on Bobst presses, with exceptional register accuracy—even in BOBST’s demanding oneECG gravure process at over 300 m/min.

Backing this innovation is a strategic collaboration with LG Chem, formalized through an MoU on 28 November 2024. The partnership leverages LG Chem’s expertise in polymer compounding with Reifenhäuser’s extrusion know-how, aiming to produce cost-competitive, high-quality MDO-PE films for recyclable packaging. The recent rollout of the world’s first 18 µm MDO-PE film is now scaling toward mainstream adoption. As Bernd Reifenhäuser, CEO, remarked, the alliance aligns raw materials, extrusion precision, and production reliability—enabling recyclable mono-material films to transition from concept to mass production. Dr. Lee Choong Hoon of LG Chem praised the partnership’s establishment of “unprecedented records in downgauging”—while confirming that further material reduction remains under active development.

The collaboration’s commercial aim is clear: make recyclable packaging not just environmental idealism, but an economically viable, mainstream solution. That goal is underscored by the common industry benchmark: replacing a 12 µm PET layer with a 16–17 µm MDO-PE, offering parity while ensuring recyclability. With the EVO Ultra Stretch already achieving 18 µm reliably, the MoU targets cost-efficient packaging that aligns with consumer expectations and regulatory demands.

Reifenhäuser didn’t stop at blown film innovation. The event also unveiled the MIDEX 11‑2500 cast film line, now equipped with integrated MDO. Designed for a variety of films—CPP, CPE, barrier variants, hygiene materials—this platform supports material downgauging while preserving performance. By enabling thinner, mono-material films that match multilayer laminates in strength and barrier function, the MIDEX line contributes to reducing material consumption and waste—a critical step toward circularity.

Photo Credit: Messe Düsseldorf

Automation, too, formed a core theme at K‑Preview, centered around PAM (Precise, Autonomous, Mechatronic). This intelligent system replaces traditional manual bolt adjustments in coextrusion adapters and dies with digitally controlled actuators. The result is consistent film quality, dramatically reduced energy use—up to 99% less than conventional thermal-bolt setups—and reduced operator skill requirements, bolstering safety, uptime, and productivity. PAM exemplifies Industry 4.0 principles: smart, efficient, and adaptive manufacturing that supports sustainability goals through precise control and energy optimization.

Thermal management received special attention through Kdesign, Reifenhäuser’s cooling technology arm. The highlight was the KARAT cooling ring, capable of boosting output by up to 50% on mid-range operations and improving performance by 25% compared to top-tier competitors. This new standard in cooling efficiency helps meet the growing pressure for speed and quality without excessive energy or material usage.

In hot or humid production environments, the CENTRO‑Freeze secondary cooling system delivers another leap in efficiency. Installed just before the film lay-flat stage, CENTRO‑Freeze reduces film temperature by up to 12 °C, effectively preventing blocking and eliminating reliance on anti-blocking additives. That means fewer materials in the mix, more reliable production under heat stress, and a payback within a couple of hot summer cycles. Users can digitize monitoring with inline temperature sensors and rely on automatic format adjustment during bubble diameter changes—delivering both energy savings and operational convenience.

To support global deployment, Reifenhäuser announced the opening of a new Service Hub in the UAE, complemented by increased support networks across the MEA region. This facility offers local installation, commissioning, spare parts, and expert training—critical for maintaining service uptime and supporting regional market growth. By placing capabilities closer to clients, Reifenhäuser enhances responsiveness and helps partner companies integrate sustainable technologies smoothly.

K-Preview 2025 set a powerful tone ahead of the full K 2025 expo in October, framing Reifenhäuser as not just an equipment vendor but a strategic partner for sustainable packaging transformation. The cohesive display—from MDO and cast film to automation, cooling, and global service—underscores a comprehensive commitment to enabling circular plastics. The timing is perfect. With consumer demand for recyclable products and legislative initiatives such as the EU’s packaging waste directive pushing for change, film downgauging and mono-material packaging are now short-term imperatives. The potential to lower material usage by 25% with PET-level performance provides manufacturers with much better margins and environmental credentials.

On the broader industry front, Drupa 2024 already showcased high-barrier recyclable films; now, K-Preview reinforced the convergence of recycling and extrusion at trade events. Meanwhile, competitors like Erema are focusing on recycling systems, signaling a unified push across value chains toward circular solutions.

Looking ahead, Reifenhäuser and LG Chem are continuing joint R&D toward films thinner than 18 µm and free of PFAS—all while refining formulations, ensuring extrusion stability, and meeting performance targets. Applications are poised to expand beyond flexible packaging into medical, hygiene, and high-barrier food applications—all benefiting from mono-material simplicity and full recyclability.

As production ecosystems embraced by K‑Preview demonstrate, the future of plastics lies in digital, energy-optimized, recyclable manufacturing. Technologies like EVO Ultra Stretch, MIDEX, PAM, KARAT, and CENTRO‑Freeze are not stand-alone innovations—they form an integrated infrastructure enabling digital continuity, resource efficiency, downgauging, and environmental responsibility.

Reifenhäuser’s clear message: sustainability and profitability are neither optional nor conflicting—they’re inseparable. By delivering technical innovation in film production, barrier technology, automation, cooling, and service networks, the company is building a pathway for global packaging manufacturers to adopt circular, high-performance, cost-effective solutions.

That vision has immediate resonance. With regulatory deadlines nearing and consumers demanding greener packaging, the time for recyclable mono-material film is now. Reifenhäuser’s approach may well redefine industry expectations—and manufacturers who adopt these systems early could gain a competitive head start in cost, compliance, and brand appeal.

In sum, K‑Preview 2025 was more than an exhibition—it was a manifesto for the future of plastics. By combining revolutionary machine design, strategic raw material partnership with LG Chem, digital controls, thermal innovation, and global service expansion, Reifenhäuser has delivered a credible, scalable, and profitable path to circularity. Their message is clear: the plastics economy of tomorrow will be circular, high-performing, and meticulously engineered, and Reifenhäuser is paving the road.

https://reifenhauser.com/

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MAAG Group Strengthens International Strategy Through SIKORA AG Acquisition

MAAG Group Strengthens International Strategy Through SIKORA AG Acquisition

A global leader in polymer processing systems and solutions, the MAAG Group has formally announced the completion of its acquisition of SIKORA AG, a premium provider of cutting-edge technology for measuring, control, inspection, and sorting. The acquisition further demonstrates MAAG Group’s long-term commitment to expanding its capabilities and global presence and marks a critical milestone in the company’s strategic expansion plan.

Established in 1973 and based in Bremen, Germany, SIKORA AG has earned a solid reputation over the years for providing cutting-edge technological solutions to various industries such as cable, pipe, hose, tube, sheets, and plastics. The firm has consistently set new standards in accuracy, dependability, and process efficiency with its portfolio of groundbreaking equipment and smart software solutions that improve quality inspection, minimize waste, and optimize production efficiency. With operations and alliances in over 80 nations, SIKORA’s international reach is supplemented by the MAAG Group’s large footprint of locations and service centers.

By joining forces, MAAG and SIKORA are poised to unlock new technological synergies and accelerate their shared mission of delivering integrated, high-performance solutions that meet the growing complexity and quality demands of polymer and industrial processing worldwide. The collaboration will enable the companies to align their R&D strengths, broaden their product portfolios, and offer expanded customer support in both established and emerging markets.

Ueli Thuerig, President MAAG Group

“We are very pleased about this partnership. By combining our strengths and expertise, we are ideally positioned to create additional value for our customers, drive innovation in a targeted manner, and promote the long-term growth of both companies,” said Ueli Thuerig, President of MAAG Group. This statement reflects the Group’s strategic intent to not only grow its technological capabilities but also to co-create solutions that will define the next era of smart, efficient, and sustainable manufacturing.

With both firms preparing for closer cooperation, the integration of SIKORA’s cutting-edge quality inspection technology with MAAG’s reliable system solutions is poised to bring considerable advantages to customers in a wide range of industries. From inline measuring in real-time to non-destructive testing and artificial intelligence-based sorting systems, SIKORA’s technologies will maximize the accuracy, transparency, and productivity of polymer processing lines. The MAAG Group, meanwhile, has its own massive expertise in melt pumps, filtration, pelletizing, and pulverizing technologies — a complete end-to-end value chain from raw material handling to end product quality control.

Dr. Christian Frank, CEO SIKORA AG

Dr. Christian Frank, CEO of SIKORA, expressed enthusiasm about the merger: “We are proud to be officially part of the MAAG family now. This partnership goes far beyond standard cooperation – it is based on a shared commitment to innovation, entrepreneurial spirit, and sustainable action, which form the foundation for long-term success. It marks an important step in our shared future, opens up a wide range of opportunities, and strengthens our ability to develop innovative solutions. We look forward to working with MAAG to continue our success and growth in a sustainable way.”

Also, this acquisition indicates a greater emphasis on digital transformation and sustainability, two important tenets of both businesses’ corporate philosophies. MAAG and SIKORA are ready to take on industry issues like energy efficiency, circular economy imperatives, and smart manufacturing—all while upholding the highest quality standards—by combining operational strengths and forward-thinking tactics.

As the integration process moves forward, both teams are focused on aligning organizational structures, investing in joint innovation projects, and ensuring uninterrupted service for customers and partners. The expanded team will continue to operate under their respective brands, reinforcing market confidence while paving the way for a unified approach to delivering cutting-edge technologies and services.

The MAAG-SIKORA partnership will eventually create new value streams by setting new benchmarks for accuracy, sustainability, and customer-focused innovation in addition to product integration and global reach. Driven by shared ideals and a goal to lead the worldwide development of polymer and industrial processing technologies, the acquisition marks a watershed in the history of both businesses.

https://maag.com/
www.sikora.net

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Innovative Polyurethane Applications Driven by PUre Synergy at K 2025

Innovative Polyurethane Applications Driven by PUre Synergy at K 2025

Interesting solutions are produced by greater knowledge: KraussMaffei will be showcasing two applications with ColorForm and Pure glycoLine PU at K 2025 in Düsseldorf (October 8–16). In these applications, polyurethane processing from the Reaction Process Machinery division (RPM) works with injection molding technology and extrusion, respectively. Process dependability and long-term value generation are the objectives. The only business that can provide equipment and procedures for the complete polymer processing chain from a single source is KraussMaffei.

Dr. Frank Szimmat Managing Director of KraussMaffei Technologies, Photo Credit: Messe Düsseldorf
ColorForm stands for the highest surface quality and efficient series production in an integrated process. KraussMaffei is the only supplier to offer all technologies from a single source – this creates real added value for our customers said, Dr. Frank Szimmat Managing Director of KraussMaffei Technologies.

The environmental regulations for spray painting are constantly becoming stricter and are causing a boom elsewhere. ColorForm, the painting of thermoplastic components using PU flooding, is experiencing a steep rise around 15 years after its development.

At K 2025, KraussMaffei and its partner Leonhard Kurz are taking technology integration even further and combining ColorForm with a film decoration system for which a new type of mold-integrated film thermoforming concept has been developed.

The application can be seen live on a GXW 650 (with swivel plate) at the Leonhard Kurz booth (Hall 5 / A19). The innovative 3K demonstrator component, based on a headlight (length 720 millimetres), was designed in such a way that the design film provided by Leonhard Kurz is back-injected with a crystal-clear and a black polycarbonate using the in-mold labeling process.

As PC would yellow due to UV radiation and headlights are exposed to stone chips and similar stresses, the component is given its crystal-clear polyurethane coating directly in the mold.

Paint layer accurate to a tenth of a millimeter

Ready-painted straight from the injection mold: the ColorForm process gives thermoplastic components a PU coating. This can be adjusted in terms of color and feel – and is also self-healing if desired.

The complete system from KraussMaffei combines reaction process machinery and injection molding technology.  With ColorForm, the PU lacquer layers can be precisely adjusted in the tenth of a millimeter range. A range of different effect and lacquer colors are available, which, in combination with variable haptics, enable a variety of design options.

In addition to protection against chemical influences, a self-healing effect is also possible – for example in the case of fine scratches on the surface. Another visual advantage is the characteristic depth effect that ColorForm creates. The metering machines manufactured by them enable output rates of up to 500 g/s and are therefore also ideally suited for large-format components.

Suitable metering units are available for adding color, so that even demanding design requirements in the vehicle interior or on the vehicle exterior can be precisely implemented.

KraussMaffei supplies all the components of ColorForm technology as a turnkey solution from a single source – from the injection molding machine and PUR metering technology to fully integrated automation.

Industrial recycling of PU with a high proportion of foreign matter

Sustainable cycle thanks to purity gycoLine PU: The PU components of items such as refrigerators are converted into polyol with recycled content (rPolyol) at the end of their service life using an extruder in a continuous chemical process.

Photo Credit: Messe Düsseldorf

This serves as a starting material for new applications and can be processed in the metering machine without any adjustments.  PU is also frequently used for insulating applications such as refrigerators, and at the end of the appliances’ life, the question of disposal arises. Until now, PU from old refrigerators has often been incinerated, for example to generate energy in cement production, but it is foreseeable that the thermal recycling of plastics will be more restricted in the near future.

KraussMaffei is therefore in the process of industrializing a process for the continuous chemical recycling of PU through depolymerization. The project partners are BASF, Rampf (Producer of sustainable recycled polyols) and Remondis (processing and recycling of old electrical appliances).

In the purity glycoLine PU process, PU insulating foam from the Remondis refrigerator recycling plant is recycled within minutes using a co-rotating twin-screw extruder (ZE BluePower). Unlike the widely known batch process, this continuous extrusion method can efficiently handle PU regrind with contamination levels of up to 30 %, including residues of other plastics and metals.

In order to achieve depolymerization using a glycolysis process modified by RAMPF, the PUR regrind is mixed with depolymerization agents and other additives in the extruder. KraussMaffei has adapted the filtration technology required for this to the market requirements for polyols in extensive tests at its Innovation Center.

The polyols obtained from the extruder can be used at BASF as a component of innovative PU systems for the production of rigid foams with recycled content. What is particularly important here is that the process is already economically attractive today.

Metering machine ready for digitalization and autonomous operation

RimStar metering machine with new digital features: the machine and process are even easier to control, even for less experienced users. The vision for the future is autonomous operation.

At the K trade fair, visitors to the KraussMaffei booth can experience live how the PU system with recyclate content is processed into foamed insulators for beverages.

The Reaction Process Machinery team will be presenting another market launch: a RimStar series metering machine with numerous new features in preparation for digitalization and autonomous operation.

This will make the machine and process even easier to control, even for less experienced users – in future, it should even be possible to completely relieve operators of certain tasks.

Digital analysis tools such as the dataXplorer, which records and evaluates all relevant process data, are already integrated for this purpose. In future, its results will serve as the basis for automatic adjustments during the production process.

www.kraussmaffei.com

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Transforming Trash into Treasure: The Future of Plastics Begins at K 2025

Transforming Trash into Treasure: The Future of Plastics Begins at K 2025

As the world’s largest trade fair for plastics and rubber again comes to Düsseldorf this October 8th to 15th, BASF is once more on board – as it has been for every single K-Fair since the first one in 1952.

“This year, we manifest our commitment to the plastics industry, and we continue our commitment to sustainability and innovation through our global campaign, #OurPlasticsJourney. More than just a tagline, it reflects our ambition to transform the plastics industry. This journey takes time, but the destination is clear: a circular economy of plastics,” emphasizes Martin Jung, President of BASF Performance Materials.

During the K-Preview press conference of June 17, BASF has revealed the first impression of what customers can look forward to at K 2025: pioneering applications designed to customers’ requirements and highlighting genuine progress in circularity in multiple business areas and industries.

Photo Credit: Messe Düsseldorf

A product portfolio evolving toward a lower carbon footprint

BASF launched its LowPCF and ZeroPCF portfolios at K 2022 as ways to employ renewable electricity, low-emission steam, and renewable raw materials in a mass balance approach to lower the Product Carbon Footprint (PCF) by at least 30%. VAUDE’s bike backpack, which uses Ultramid ZeroPCF—the first polyamide 6 in the market to reach a CO2 footprint of net zero—is a recent example of a ZeroPCF product innovation.

Building on this, BASF has now launched a reduced PCF product range, rPCF, aimed at PCF improvements using renewable electricity and steam alongside the production process. The offering is now available in BASF’s Engineering Plastics and Thermoplastic Polyurethanes sustainability toolbox. It follows BASF’s achievement of completely switching all its European Performance Materials plants to renewable electricity powered by solar and wind energy.

Make becomes circular

While technology and processes are major levers of transformation, the use of alternative raw materials is equally essential. At K 2025, BASF will showcase products for which fossil resources are replaced with renewable feedstock at the beginning of the production process using the Biomass Balance approach. This helps reducing the carbon footprint of:

  • Siemens circuit breaker SIRIUS 3RV2: Ultramid BMB and Ultradur BMB
  • Certified compostable and soil-biodegradable biopolymers: ecovio and Ecoflex BMB
  • ZARA bodysuit: Ultramid BMB

Additionally, BASF replaces fossil resources with feedstock from the chemical recycling of plastic waste in a mass balance approach for its Ccycled portfolio:

Transformation is not only about materials, but also about data. As the industry moves toward greater transparency and accountability, digital tools become essential to enable and accelerate the green transformation. To support this, BASF offers the PACIFIC app that provides standardization and interoperability in PCF data exchanges of plastic materials. Designed for ease of use, the PACIFIC app is seeing growing adoption across stakeholders in the value chain.

Alexander Weiser, Senior Vice President, Head of BASF, Photo Credit: Messe Düsseldorf
“With rPCF, we are giving customers flexibility to customize their products’ carbon footprint by opting for renewable energies in our production process. This is a logical next step in both their green transformation and ours,”- Alexander Weiser, Senior Vice President, Head of BASF.

Use of plastics’ strengths

Plastics bring unique benefits to many applications that often extend their lifespan. This is particularly important for future technologies, such as the production of green hydrogen. For example, Ultrason S3010 (PSU: polysulfone) enables the production of larger, more robust and durable parts like frames in stacks for alkaline electrolyzers developed by Stargate Hydrogen.

In high-performance household appliances like the latest Thermomix by Vorwerk Elektrowerke, BASF’s engineering plastics, Computer-Aided Engineering (CAE), and testing capabilities support complex applications. Several parts are made of either Ultramid  Advanced N (PPA: polyphthalamide) or Ultramid A (PA66: polyamide 66), selected for their high temperature stability and mechanical strength respectively.

In the eMobility sector, BASF has developed a next-generation battery demonstrator featuring advanced plastic material solutions to enhance lightweighting, thermal management, safety and performance.

Recycle is the new Make

As part of its commitment to a circular plastics economy, BASF is scaling up complementary recycling technologies to give waste a second life. Across various industries – packaging, furniture, appliances, textiles and vehicles – new solutions demonstrate how recycling becomes an engine of innovation.

To support efficient recycling processes, BASF subsidiary trinamiX provides a handheld tool for fast and reliable identification of different plastic and textile types. The trinamiX Mobile NIR Spectroscopy Solution facilitates cleaner sorting and improved recycling outcomes.

For paper-based food packaging, BASF extends the end-of-life options to organic recycling. Its tailored certified home and industrial compostable ecovio allows coating on paper food articles to achieve necessary barrier properties, especially for liquid and fatty ingredients.

As a leader in the polyurethanes (PU) business for more than 60 years, BASF is committed to demonstrating PU’s versatility and recyclability:

  • Together with its long-standing partner Vitra, BASF is showcasing the world’s first economically recyclable flexible foam for furniture.
  • In collaboration with Krauss Maffei, Rampf and Liebherr, BASF is also developing an efficient chemical recycling process to return polyurethane to the same material cycle. In a stable, continuous industrial depolymerization process, recycled polyols are produced, which can be used to manufacture new PU rigid foams as insulation material in refrigerators. By using post-consumer waste from end-of-life refrigerators as feedstock, the consumption of fossil resources can be significantly reduced.

Thermoplastic polyurethanes (TPU) also enter the circular economy: the new Elastollan RC grades include up to 100% recycled content with close to virgin performance by re-using post-industrial and post-consumer TPU waste.

With loopamid, BASF has developed an innovative solution to improve circularity in the fashion industry and recycle post-industrial and post-consumer polyamide 6 textile waste over multiple times.

Finally, BASF is advancing numerous projects in the recycling of automotive plastics via mechanical recycling, solvent based recycling, depolymerization and high temperature recycling such as gasification.

www.basf.com

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Precision Extrusion Innovations Lead the Way at K 2025

Precision Extrusion Innovations Lead the Way at K 2025

Performance. Perfected. For you – with this slogan, KraussMaffei will be presenting at K 2025 (Düsseldorf, October 8th – 16th) how leading-edge technologies and a top customer orientation provide measurable added value. The focus of extrusion technology is on solutions for more efficient and future-oriented plastics processing – from large-scale industrial polymer production to pipe and profile extrusion and to efficient recycling processes. The trade fair appearance will be supplemented by digital innovations to enable smart, low-operator production.

Photo Credit: Messe Düsseldorf

The development roadmap for the coming years is clearly defined: “We are working specifically on new developments to continuously increase customer benefits, actively maintaining our products and resolutely driving forward the digitalization and automation of our products.” This is how KraussMaffei Extrusion is creating the foundation for sustainability, economic success and technological progress. “And we are making this tangible for visitors at K 2025 in Düsseldorf,” says Ralf Benack.

Future market petrochemicals: New processing extruder for raw polymer production

One of the latest significant advancements is the latest generation of ZE Petrochemical (ZE-PC) compounding extruders, specifically designed for the high requirements of large-volume polymer manufacturing. Drawn from the successful BluePower technology, the co-rotating twin-screw extruders – with screw diameters up to 400 mm – integrate energy efficiency with superior processing quality.

“Thanks to a D/d ratio of 1.65, torque densities of up to 16 Nm/cm³, and variable-speed drives, the machines can run at lower screw speeds without compromising throughput. This lowers the specific drive power and reduces the melt temperatures, which lowers the risk of degradation,” explains Dr. Thomas Unger, Vice President Technologies at KraussMaffei Extrusion. At the same time, the larger diameter ratio ensures significantly more effective degassing. “This allows us to offer our customers an economical, reliable and material-friendly solution,” he adds.

Ralf Benack, Managing Director of KraussMaffei Extrusion GmbH, Photo Credit: Messe Düsseldorf
“Performance. Perfected. For you. reflects our commitment to delivering advanced extrusion solutions – technically refined, highly efficient, and consistently geared to the requirements of our customers, Our strength lies in the combination of highly developed mechanical engineering and deep process know-how – all from a single source, reliably delivered worldwide.” –  Ralf Benack, Managing Director of KraussMaffei Extrusion GmbH

Increased output, reduced investment – cost-optimized recycling processes

Bottle-to-bottle PET recycling to material preparation for chemical processes – as a circular economy innovation driver, KraussMaffei Extrusion provides trailblazing solutions for any type of recycling. In the field of PET recycling, KraussMaffei Extrusion is showing a high-performance twin-screw system from the BluePower series for throughputs of up to 12 tons per hour. The technology answers the growing need for greater output and more energy- and cost-effective processing. It is up to 20% lower in energy consumption compared to traditional twin-screw systems. They are compatible with standard SSP units and yield food-grade rPET.

In chemical recycling, KraussMaffei Extrusion is focusing on key technologies: high-performance extruders for processing material streams – for example, to produce pyrolysis oils – efficiently implement crucial process steps such as dewatering, degassing and the removal of impurities. Pressures of up to 200 bar and the retractable UltraGlide system with easy-to-maintain screws enable customized solutions for demanding recycling applications.

KraussMaffei Extrusion has also refined its EdelweissTechnology for processing recyclates more efficiently – even with fluctuating material properties. The focus is clearly on process optimization and cost efficiency. The twin-screw extruder covers all process steps: degassing, filtering and compounding. “This integrated setup can lower investment costs by up to 25%,” says Dr. Thomas Unger.

More efficient research, more economical production: ZE BluePower in a new design

Whether for research or daily production – the new generation of the ZE BluePower twin-screw extruders offers clear advantages. The new ZE 28 BluePower scores with improved operation, greater energy efficiency and digital networking via ppC (pioneer processControl). The larger ZE 42-80 series has also been comprehensively redesigned – with a focus on simple maintenance, digital interfaces and an optimized modular system. “For our customers, this means a better price-performance ratio and shorter delivery times – real advantages in day-to-day operations,” says Dr. Thomas Unger.

New multilayer pipe head processes up to 100% recyclate

With its newly developed PVC multilayer pipehead, KraussMaffei Extrusion is demonstrating how pipe and profile extrusion can be made more sustainable and future-proof. The system processes up to 100% recycled PVC – even with varying material quality. The layer configuration can be flexibly adjusted depending on the application. A newly designed flow system prevents spiderlines and ensures consistent product quality with optimal material usage.

Digital transformation: rethinking machine control

With the new ppC (pioneer processControl) control system, KraussMaffei is bringing greater clarity and efficiency to extrusion processes. Instead of complex operating logic, ppC relies on intuitive processes, clearly structured user guidance and a unified user interface. This shortens the learning curve, reduces the amount of training required and makes everyday production easier. Its modular design enables use across all extrusion tasks – from Flat & Foam to Pipe & Profile through to Compounding and Recycling.

Integration into existing systems is also easy: interfaces for connecting to third-party devices such as metering devices, measuring systems and higher-level systems such as MES or DCS enable the central operation and monitoring of entire systems. This ensures greater transparency and process reliability.

Looking ahead: on the way to production without operators

In view of growing staff shortages, KraussMaffei Extrusion is developing digital tools for production without operators (PWO). Start-up workflows, AI-supported assistants and HMI solutions for mobile use make it easier to monitor entire lines – with fewer personnel. The first systems are already running unmanned at weekends – a milestone towards lights-out manufacturing.

Tailor-made Lifetime Service for maximum system efficiency

With its Lifetime Service, KraussMaffei Extrusion offers a comprehensive service concept that goes far beyond routine maintenance. “From commissioning and targeted modernization and data-based services, we support our customers throughout the entire life cycle of the system – reliably, proactively and with personalized solutions,” says Ralf Benack. Whether it’s spare parts, remote support, training, or digital condition monitoring, the goal is always the same: maximum plant availability, consistent product quality, and a sustainable boost in overall efficiency.

Performance. Perfected. For you.

KraussMaffei Extrusion’s presence at K 2025 underlines its commitment to combining innovative technologies, sustainable solutions and maximum cost-effectiveness in perfectly coordinated system solutions – individually tailored to customer requirements along the entire polymer processing value chain.

www.kraussmaffei.com

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Where Sustainability Meets Precision: Advanced Extrusion Takes the Spotlight at K 2025

Where Sustainability Meets Precision: Advanced Extrusion Takes 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.

Dr. Henning Stieglitz, CEO of battenfeld-cincinnati Group, Photo Credit: Messe Düsseldorf
“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.”

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.

Photo Credit: Messe Düsseldorf

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.

battenfeld-cincinnati, sustainable solutions worldwide

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.

https://www.battenfeld-cincinnati.com/

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K 2025 Puts Customer-Focused Precision and Peak Performance in the Spotlight

K 2025 Puts Customer-Focused Precision and Peak Performance in the Spotlight

Under the motto “Pioneering Plastics – Performance. Perfected. For you.”, KraussMaffei will present itself at K 2025 as a total solution provider throughout the entire polymer processing value chain. Injection moulding technology, automation and additive manufacturing will concentrate on new technologies for ultimate efficiency, highest component quality, sustainability and uniform digitalization. The trade fair features include the innovative new all-electric PX series with simple MC7 control, the new Chopped Fiber Processing (CFP) process, an automated production line as well as digital solutions and innovations in additive manufacturing.

“What sets KraussMaffei apart is the unique combination of innovative mechanical engineering, profound expertise in process technology and intelligent digital solutions. And this in the areas of injection molding, automation, reaction process machinery, extrusion and additive manufacturing,” explains Jörg Stech, CEO of KraussMaffei Technologies GmbH. This portfolio is complemented by a global, high-performance service that supports customers throughout the entire product life cycle – with fast response times, maximum availability and digital tools such as the pioneersClub. “Our aim is to develop future-proof and sustainable solutions for our customers. Cost-effectiveness is clearly our top priority – and that’s exactly what we’ll be demonstrating live at K 2025 in Düsseldorf.”

PX series redefined: Compact, powerful, sustainable

A highlight at the KraussMaffei stand will be the world premiere of the all-electric PX injection molding machine series. The new generation impresses with outstanding energy efficiency, excellent shot weight consistency and short cycle times. The machines offer a wide range of applications and high overall equipment effectiveness (OEE) “The new PX machines from KraussMaffei are the most advanced injection molding machines on the market. Their attractive price-performance ratio and long service life make them a future-proof investment for our customers,” explains Jörg Stech.

Besides cost efficiency, the new series is also centered on sustainability: due to cutting-edge drive technology with energy recovery, low media consumption and a resource-efficient machine design, the PX machines provide highest values in energy efficiency during operation as well as during idle operation. Through their compact space requirements, they also allow flexible production cells with built-in handling and conveyor technology – perfectly optimized for the demands of modern manufacturing.

Live at K: New PX series with new LRXplus linear robot

At K 2025, KraussMaffei will be presenting the new all-electric PX series together with the new LRXplus linear robot. The LRXplus series provides versatile functions for flexible automation and is noted for high compatibility, both with KraussMaffei injection molding machines and with machines of other manufacturers as well as with different automation tasks.

Attendees at the trade fair will be able to see for themselves the cost-effective combination of PX machine and LRXplus robot in live operation at the KraussMaffei stand. Future-oriented applications in medical technology, technical components and packaging/logistics will also be presented.

Photo Credit: Messe Düsseldorf

New MC7 control generation: More power, more operating convenience

With the MC7, KraussMaffei presents a modern, web-based control platform. It impresses with its intuitive operation, powerful software and hardware architecture and the highest security standards. The MC7 architecture already includes the upcoming requirements of the Cyber Resilience Act (CRA). This means that the control system is even better protected against cyber-attacks and the distribution of malware. The CRA standard also makes it easier to connect machines to the network for digital data usage.

Another feature of the new MC7 control system is the new, web-based visualization concept, which impresses with its intuitive user guidance, clear display and extended functionality. The new interface makes set-up, operation and maintenance easier and increases efficiency in day-to-day production.

Revolutionizing the processing of chopped glass fibers

With the new Chopped Fiber Processing (CFP) process, KraussMaffei presents an economical solution for direct compounding of chopped glass fibers and polypropylene. Compared to conventional long glass fiber pellets, CFP offers significantly greater flexibility and noticeable cost advantages – while maintaining the same component performance.

At the heart of the process is a newly developed, patented screw geometry that ensures particularly efficient melting and homogeneous mixing of polymer and fibers. The result: high-quality, fiber-reinforced components with optimum material utilization.

Another advantage: CFP is compatible with all KraussMaffei standard injection molding

machines and can be easily retrofitted via the KraussMaffei Service. The return on investment (ROI) is less than one year. “The CFP process from KraussMaffei is currently unique on the market. For the increasing demand for fiber-reinforced plastics, we offer a real game-changer with the CFP solution to significantly reduce material costs,” explains Jörg Stech.

Visitors to the K 2025 can experience the CFP process live at the KraussMaffei stand on a GX 650-4300 in combination with a LRXplus linear robot. A complex tailgate component for the automotive industry will be produced, providing practical proof of the capabilities of the new technology.

When every part fits perfectly – Automated assembly cell

KraussMaffei is expanding its automation portfolio beyond injection molding technology to include autonomous automation cells that are versatile and easy to integrate. At K 2025, the company will be presenting a fully automated assembly cell that assembles three plastic parts in real time – without any manual intervention. The mobile, compact unit enables particularly short cycle times with a minimal error rate.

Assembly is carried out by form-fit clipping of the components. A laser scanner then checks the height and width of the components with an accuracy of 0.01 mm. An optical inspection automatically detects and sorts out faulty parts, while the good parts are filled directly into boxes.

Digitalization that makes the difference

Digital solutions that increase efficiency and make everyday production noticeably easier are an integral part of their strategy. Numerous innovations will be presented at K 2025: With the Dataset Manager, the socialProduction platform will receive new functions for transferring, versioning and comparing machine data sets. A new AI function supports machine operators with intelligent assistance in real time. Two new modules are being added to the tried-and-tested and patented APCplus machine function: cascadeX for cascade control and the new materialX database for customer-specific material parameters.

Additive manufacturing: Large format printing on a new level

Following the successful launch of the powerPrint at K 2022, they are presenting the new powerPrint FLEX and printCore variants at K 2025. These modular systems offer maximum flexibility, high productivity and excellent print quality for industrial applications – e.g. in design, mold making and functional end components.

As part of a live demonstration, KraussMaffei will be showing the powerPrint FLEX in combination with the new printCore extruder in an industrial robot cell. The focus will be on mold and die making applications as well as functional end-use parts and design models.

www.kraussmaffei.com

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