Way2K: Industry interviews in the run-up to K

Our society faces challenges such as climate change and resource conservation. The plastics industry plays a central role in this. At K 2025, the focus will be on the circular economy, digitalisation and responsibility towards people and the environment – all of which are crucial for sustainable development.

The VDMA is inviting representatives from the plastics machinery sector and other stakeholders to take part in weekly interviews to share their perspectives. These discussions highlight our responsibility to support skilled workers and to harness the potential of plastics for a better future.

Results (28)

  • "Artificial intelligence is a decisive competitive factor and helps alleviate the shortage of skilled workers"

    Interview on the way to K 2025 with Dipl.-Ing. Michael Wittmann, President of WITTMANN Group Michael Wittmann; Copyright: Wittmann Group Mr. Wittmann, is the low oil price the reason why things have quietened down somewhat in the circular economy recently? Michael Wittmann: In Central Europe, sustainability continues to be a driver of innovation. However, the issue has taken a back seat because of political and economic developments. In our view, this is not only due to the oil price, but also because of the tense economic situation within many companies. Investments are being cut back, which is slowing down technological development. We should be prepared however for the EU to impose recycling quotas at some point, especially for the packaging and automotive industries. When that is the case, we should have good PCR qualities available and experience in processing them. It is important, however, that sustainability is economical; something we bear in mind at the Wittmann Group in all new and future developments. How do you achieve that? Wittmann: We place value on overall efficiency, and highlight potential savings across our entire product portfolio, from peripherals and automation to injection moulding machines. The focus is on energy consumption, time, space requirements and material usage. We always attach great importance to an optimal cost-benefit ratio. When using recycled materials, an increasing number of customers rely on consistent inline or in-house recycling. This results in very pure recycled material that can then be used directly in many applications. We offer a complete work cell consisting of an injection moulding machine, a mill and, upon request, a gravimetric dosing device and conveyor equipment. This allows you to increase material and cost efficiency, significantly improve your carbon footprint and reduce waste. It even opens up new design possibilities for product development, and perhaps even completely new business models. How might these take shape? Wittmann: At K, we will be presenting the "Wild Pot" project with Wildplastic GmbH from Hamburg. They collect plastics from the environment and process them. We will show how it is then processed – at K, for example, into a flowerpot. This is challenging because the plastic is only sorted by type and therefore varies in material quality. To compensate for this, we use High Q-Flow in the injection process. Of course, using this type of PCR cannot be cheaper than virgin material. This means that companies that use collected "wild plastic" must be committed to sustainability and willing to spend more on it. This is, of course, a niche application. The products do not appeal to the general consumer, but rather to the environmentally and climate-conscious consumer who wants to do something for future generations. How strong is the influence of economic developments? Wittmann: Fundamentally, the circular economy is not independent of economic cycles, because it is always easier to put innovations into practice when times are good. At the moment, however, there is a general reluctance to invest, and this can detain the entire market in terms of technological development. On the other hand, it is precisely in these times of weaker demand that opportunities arise to tap into new markets, implement new ideas, and develop innovative products. What are the drivers of innovation in plastics machinery manufacturing? Wittmann: Sustainability continues to be the main driver of innovation, alongside digitalisation and cost pressure. Cost efficiency considerations are leading to a further focus on the essentials. Tailor-made systems without the many extras that are otherwise found in specifications, in order to reduce investment costs, but, and this is very important, without compromising on quality. We call these variants Primus, and we offer them in all product areas. The new fully electric EcoPrimus injection moulding machine, for example, will be on display at K. We are also aware that innovations are increasingly user-driven. The Wildplastic® project is one example of this. In the circular economy in particular, there is considerable potential for efficiency and quality gains along the entire value chain. Does artificial intelligence play a role? Wittmann: In the OT area, extensive work is currently being carried out on applications because they represent a decisive competitive factor, especially where AI supports the operator in decision-making. In assistance systems for tool setting, for example, in predictive, condition-based maintenance or even in troubleshooting. At the trade fair, we will be presenting AIM4Help, an AI-based large language model for troubleshooting that can be queried normally, or accessed by reading QR codes on the machines. Such systems clearly help to alleviate the shortage of skilled workers, as they reduce the need for trained personnel. How is the Wittmann Group positioning itself in the face of growing Chinese competition? Wittmann: We are maintaining our high level of innovation. Like all European suppliers, we score highly in terms of customer proximity and system solution expertise, which is in high demand among our customers. Application technology consulting and service are and will remain our strengths. As the Wittmann Group, however, we are also exploiting the potential of our international production network. We are expanding our plant in China in order to serve China itself and the Asian market from there. How important is K in this context? Wittmann: Very important. I think that right now, the industry needs fresh impetus from the market, and K has come at exactly the right time. We receive valuable feedback there on global trends and topics. On the one hand, I am looking forward to presenting our new technologies and products, while on the other, I am looking forward to personal discussions with our customers, as personal contact is a decisive key for project success. Source VDMA Way2K 2025

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  • "It is still important for humans to operate machines"

    Interview on the road to K 2025 with Dr Stefan Engleder, CEO ENGEL Group Stefan Engleder. Copyright: ENGEL Mr. Engleder, how important is innovation in difficult economic times? Dr Stefan Engleder: Innovation is extremely important – especially in the current climate – for our customers as well as for ENGEL. Our customers need innovative solutions to launch new plastic products in a competitive and sustainable manner, and at ENGEL, we are also investing specifically in innovation to support our customers in becoming and remaining leaders in their field. That is why, despite this crisis, which has been ongoing for the past three years, we are investing in research and development in the areas of products, processes and digitalisation, as not innovating would mean standing still, and that ultimately means taking a step backwards. How do you achieve this? Engleder: The advantage of injection moulding is its enormous versatility – from micro-applications to large-volume applications. We develop new or alternative ways of manufacturing plastic products efficiently, cost-effectively, and reliably, in close cooperation with our customers – in some cases even in moulds that have never existed before. At the same time, we are making long-term investments in research and development, in basic research, digitalisation and our assistance systems. Development cycles of four to five years are not uncommon. It often takes six, seven or eight years before marketable innovations emerge and we start earning money with them. This kind of staying power is necessary to create sustainable solutions that are also economically viable. What role does AI play in your innovation efforts? Engleder: Using the iQ process observer – the latest addition to our iQ assistance series – we support customers by means of artificial intelligence to improve process stability in injection moulding. The iQ process observer monitors the production process and provides suggestions on how to adjust the machine. The control system analyses a wide range of process parameters and uses this information to forecast how the production process will develop under the current conditions. As soon as critical deviations become apparent, the machine operator receives feedback via a traffic light system. In addition, the system also makes specific propositions for optimising the machine settings. The next step would, of course, be for the machine to adjust itself. However, we believe that it is still important for a human to operate the machine. Does AI help alleviate your customers' skills or even labour shortages? Engleder: Through utilising suggestions made by the assistance system, a new machine operator does not need to be a process engineer, but basically follows clearly structured instructions, similar to a checklist provided by the machine control system. In fact, it can be an unskilled worker, not necessarily a skilled worker. We have identified the shortage of skilled workers as a key issue at ENGEL because this topic is also actively reflected back to us by our customers. We therefore also offer straightforward set-up assistants, such as tool change assistants; that helps the machine control system to guide the operator through the process step by step. This means that the training phase no longer takes several months, but can be completed in one to two days. Thirdly, we also offer remote access options. Experts, whether from the customer or from ENGEL, can connect remotely via our e-connect portal and support the machine operator, for example with maintenance, optimisation or service. This renders savings in terms of skilled workers, and, above all, time. However, it does not help with the general labour shortage – machine operation will still be necessary. So unmanned machines are still a thing of the future? Engleder: No, I wouldn't say so. We are already relatively close, due to our expert system. I would compare it to autonomous driving in cars: they are already on the roads, not necessarily on every continent and in every city, but the technology is actually relatively mature. However, it is not enough to just develop the technology and create the conditions: you also need a wellthought-out overall concept and, above all, customer acceptance. And that raises the question of whether a completely unmanned machine is even necessary – and whether our customers actually want it in this form. At K 2025, we will be presenting an industrial solution for a self-regulating injection moulding cell for the first time. Supported by artificial intelligence, the machine is capable of autonomous production, and can optimise quality and processes independently. This is a significant milestone on the road to further digitalisation in injection moulding. Technologically, we are therefore very far ahead. At the same time, one thing remains clear to us: responsibility still lies with humans, as even the best assistance ultimately requires a conscious decision by the user. What trends do you currently see within mechanical engineering? Engleder: Electrification and energy efficiency are still continuing trends. This is currently a concern for almost everyone, because on the one hand energy consumption is a clear cost factor, and on the other hand, energy is not available without restrictions in many places. We will also be presenting new solutions in this area at K. We have already discussed the second major topic: artificial intelligence; in particular the further development of our assistance and digital systems, plus we are continuing to see a trend towards sustainability. Even though the discussion is currently somewhat less prominent due to postponed deadlines at EU level, the industry is nevertheless consistently preparing for it. After all, regardless of regulatory requirements, we have no choice but continue to promote the circular economy. The motto of K is "The Power of Plastics! Green – Smart – Responsible." The fact that "green" is explicitly included underlines the importance of this topic. How do you see the role of K? Engleder: K 2025 will certainly point the way ahead. It is the leading trade fair for the plastics industry, with a clear European focus due to its location. K may no longer be the largest trade fair in terms of visitor numbers, but it has always been and still is the trade fair for innovation and visionary ideas. I expect it once again to show where plastics processing is heading – technologically, strategically, and in dialogue with industry. We at ENGEL are looking forward to K 2025 with great anticipation and are preparing extensively for the event. It is not just about presenting new products, but also about communicating our visions to a broad specialist audience – and receiving feedback on whether these are shared. We develop a lot in close contact with our customers, but it is just as important to make these developments visible. K is the perfect venue for this; it’s the only event where you can encounter such an interested and knowledgeable audience. Source VDMA Way2K 2025

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  • "Sustainability and circular economy are absolutely essential"

    Interview on the road to K 2025 with Marcel Moeller, Global Branch Manager Plastics Industry at Baumüller Nürnberg GmbH Marcel Möller. Copyright: Baumüller Nürnberg GmbH Mr. Moeller, how does the electrification trend within the plastics industry contribute towards sustainability? Marcel Möller: The excellent efficiency of electric drive systems reduces energy consumption and, as a result, CO2 emissions. This correlates with optimised material usage, and also helps customers to manufacture their products globally, and with high process reliability. Servo hydraulics is a good example. Here, we combine the very high power density of hydraulic power transmission with the control quality and dynamics of energy-efficient electric drive systems, which, when combined with intelligent software, results in energy savings. Another example is the plasticising or screw drive, which is often one of the main energy consumers. Replacing the hydraulic drive with an electric drive saves a vast amount of energy. Productivity can also be increased, depending on the machine cycle or end product. We are also witnessing the electrification of the so-called clamping drive in injection moulding machines, but also in blow moulding machines, where energy can be recovered during the braking phase. The need for energy efficiency is not as pressing in other parts of the world as it is in Europe. Is the trend towards electrification equally strong in other regions? Möller: High energy costs are not the driving factor everywhere, but they are of course an issue. The stability of the energy supply and possible subsidy programmes are strong regional factors of influence. In Europe, the demand for energy-efficient drives is a consequence of high industrial electricity prices. In the US, developments are fuelled by CO2 emission savings to a greater degree. And in Asia, it is not necessarily energy costs, but rather the stability and availability of energy that are the catalyst in terms of the demand for energy-efficient drives. Can systems generally be retrofitted with electric drives at all stages, or is this only possible in new systems? Möller: Machines in the field can be retrofitted; this is a very good way to improve the efficiency of existing plants, especially where there is a lack of investment security. I would like to cite servo hydraulics again as an example, where we offer such retrofit solutions to end users in coordination with our machine manufacturing customers. Things have quietened down around the topic of circular economy. How do you rate its significance at present? Möller: You can already tell from the announcements about K that things have calmed down somewhat. Other topics are coming back into focus alongside sustainability: technological innovations, digitalisation and increasing productivity. Behind this is the need to arm ourselves against increasingly tough competition from Asia, but the issue of sustainability or the circular economy is absolutely essential. Global demand for plastics rose to 400 million tonnes in 2023, and is set to more than double by 2050. This shows how important and valuable plastics are as a raw material: for e-mobility, and for medical technology as a result of the sharp rise in online care and mobile health solutions. To achieve the ambitious climate targets, we have no other solution than the circular economy. Currently, only around ten percent of demand is met by recycled plastics, perhaps 15 percent in Germany. There is still enormous room for improvement, but in our opinion, this is a great opportunity to take on a pioneering role through technological innovation, and to expand or secure competitiveness. What will playing this pioneering role actually involve? Möller: The basic prerequisite is, of course, a recyclable product design, and the efficient collection and sorting of plastic waste. Recyclates must have at least the same conditions as virgin materials in terms of price and availability. I think that since K22, a lot of innovations have emerged in the field of machinery that can ensure or achieve recyclability. However, the necessary framework conditions are not yet in place. There is still significant potential for optimisation. And, last but not least, there is the issue of regulation, which should ensure fair competition, and not slow down progress or tie up time and resources. How far has mechanical engineering advanced in terms of AI, especially in drive systems? Möller: Digitalisation is an important tool for our customers to optimise productivity. One example is simulation software, which can be used to design drive components in a digital twin before they are implemented in a real machine. At Baumüller, we are pushing the topic of AI and therefore also our intelligent drive-based solutions, such as an injection regulator for injection moulding machines, energy monitoring, and a shock detection function for plasticising and shredding drives. Another example is communication interfaces in production networks with peripheral devices, or with upstream and downstream value-added stages. How do you assess the importance of K as a venue in view of the continuing difficult environment? Möller: K is an absolutely international trade fair, which sets it apart from all others. It is an important source of inspiration for innovation and sustainable solutions, and ultimately also a driver for new business development. This trade fair is extremely important as an international platform – especially in view of the current economic situation in Europe and other regions, which is not exactly ideal. Everyone is represented there, including the growth markets in Asia, which is why we're looking forward to stimulating discussions with customers and interested parties. Source VDMA Way2K 2025

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  • "Good solutions require bringing together every player"

    Interview on the road to K 2025 with Dr. Torsten Schmitz (Managing Director, Extrusion Business Unit) and Hermann Veismann (Managing Director, Printing and Finishing Business Unit) at Windmöller & Hölscher Hermann Veismann. Copyright: Windmöller & Hölscher SE & Co. KG Why will W&H be represented at the next K with both its extrusion division and printing division? Hermann Veismann: Many of our customers are active in both fields; that is why we have decided to showcase our capabilities in both areas for the first time. The range of products and services in both the printing and extrusion sectors is certainly a unique selling point for W&H. Dr. Torsten Schmitz: Our customers are facing radical change: multiple demands, including more mono-material packaging, and the processing of new raw materials, are forcing them to look at the entire global value chain. At every step of the process, it is necessary to consider what any subsequent step entails, which is simply driving the pace of change. We are noticing that our holistic focus on the overall application is very well received. This has always been a key factor at our in-house Expo exhibition, and we are now looking to make this even more visible in Düsseldorf. Why is everything now happening at a faster rate? Dr. Schmitz: The new EU Packaging Regulation PPWR is certainly an accelerator, but there are other constraints as well, such as the replacement of PFAS substances for example. In the end, you have to convert your entire raw material base and use different additives. In addition, there are supply chain issues - all changes that are coming at a very fast pace. This, in combination with very strong cost pressures, is forcing our customers to question their current methods of operation and driving forward innovation. Veismann: This is also true for the printing sector. These new material compositions go hand in hand with new material properties, which we have to master. This highlights how important a cross-discipline approach is. The developments resulting from the shift towards greater sustainability make this absolutely essential. The motto of K is confident: Green – Smart – Responsible. Do you feel this is appropriate? Dr. Schmitz: The keywords Green, Smart, Responsible are certainly appropriate. They exude a sense of confidence, and confidence is an important sign for any business. However, we must all jump on board. Our daily contact with our customers shows that everyone is facing major challenges: in product development, in product development cycles, in investments. Our job is to cooperate with our customers to find a solution for them; something we are good at, as we know all the players involved. What are the specific challenges? Dr. Schmitz: Everyone is facing their own individual problems. Many are wondering, for example, what the future holds for PCR, how much PCR content they will need, how recyclable it is, and what requirements they need to consider in terms of export markets. Many of the framework conditions are still unclear, which is causing a great deal of uncertainty among our customers. We want to advise them in this environment with an open mind towards technology, so that they will still have a competitive edge in five years' time and, if possible, grow faster than the market. Once again, the key here is cooperation between the different divisions. Veismann : Modularity is very important to our customers looking ahead, with the keyword here being retrofit capability. If a machine is optimally designed for a particular material, we are already considering how we can adjust, retrofit or convert it at little cost to meet future requirements. Customers invest a lot of money in a machine and are naturally concerned if they and their suppliers have uncertainties concerning where things are heading. Dr. Torsten Schmitz; Copyright: Windmöller & Hölscher SE & Co. KG Are there any materials that pose a challenge for your machines? Dr. Schmitz: Basically, our machines can process all materials. It is important to advise our customers. We need to understand what their needs are and where they want to go. When it comes to MDO, for example, we have customers who are already in 24/7 production. But what won't work is trying to cover a very broad product portfolio with a single machine; you can't run PCR today and MDO-PE tomorrow. It's about producing sensibly and economically on one machine and selecting the right one. How does the density of regulations in the EU compare to other markets? Veismann: In the growth markets in Asia, i.e. in India and China, we find different regulations that are being adapted at different speeds. But the regulatory density in the EU is particularly high. This applies both to the requirements for commercial enterprises themselves and to the requirements for the packaging market. Just think of the sustainability reporting obligations or the Supply Chain Due Diligence Act, which are all accompanied by considerable costs for European companies; costs that are naturally passed on to customers and therefore render a competitive disadvantage. Dr Schmitz: The rules in the EU are all well-intentioned. When it comes to sustainable packaging in particular, everyone is looking to Europe for guidance on mono-material composites and the overall life cycle of packaging. This pioneering position is appropriate for Europe, but there are also requirements that are completely unrealistic. Why, for example, should food packaging be required to be turned into food packaging again? The European Green Deal seems to have taken a back seat in favour of a more business-oriented mindset. Veismann: There is hope that there will be a shift in political priorities. Despite all the good intentions behind the regulations, the speed, consistency and leap we are taking in Europe are a threat to our location, and that naturally concerns us. I am convinced that it will not help anyone if we take Europe out of the game because it becomes uneconomical. What do you expect from the K? Dr. Schmitz: For me, the K is like a family reunion, an opportunity to exchange ideas and provide guidance. These personal meetings are very valuable, and everyone takes away new ideas – not just our customers, but we also benefit greatly. Veismann: Visitors to the trade fair are driven by opportunity. We want to convey enthusiasm for the machines and the opportunities they offer. We try to convey a vision. We define ourselves less by machine sales and more by the partnerships and the added value they offer. Source VDMA Way2K 2025

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  • "AI delivers great benefits for plastics recycling"

    Interview on the way to K 2025 with Dietmar Dieing, Vice President Sales Plast at Sesotec GmbH Dietmar Dieing. Copyright: Sesotec GmbH Mr. Dieing, how can planning certainty be provided in terms of the circular economy? Dietmar Dieing: Planning certainty is extremely important for the success of the circular economy. It can only be achieved if reliable material flows are produced, standardised recyclate quality is obtained, and stable legal framework conditions are in place; these are three prerequisites that currently do not exist; many things are lackinging. We do not yet have transparent data on products along the entire value chain; a kind of material passport so to speak. We also do not yet have the necessary partnerships between producers, recyclers and machine manufacturers, or political incentives and detailed standards. We will only be able to sort waste through our sorting machines in such a way that a waste product can later correspond to its original product once all of this is in place. Which of the above requirements is the most difficult to implement? Dieing: The most difficult are probably the political standards and incentive systems for Europe. These must ensure that everyone works under the same conditions. So far, this has only been fragmentary. For example: there is a requirement from the EU Commission that at least 30 percent of recycled materials from post-consumer waste must be used in new products as of 2030. These quotas cannot be met at present, because it is not yet clear exactly in what quality grades the recycled material is available on the market, and in which quantities. It would therefore be important to introduce a regulation stipulating that all products must be manufactured in such a way that they can be recycled. That means a Design for Recycling? Dieing: Exactly. Today, many applications still use composite materials that cannot be reasonably converted into recycled materials. Take multi-layer films in the packaging sector for instance: these consist of several different plastics and cannot be recycled in such a way to produce highquality films. Mono-layer films on the other hand are very easy to recycle because they consist of a single polymer. The material flow that is then created begins to be recyclable. The goal must be to achieve the best possible material flow, whereby we can state that everything made from this material is truly 100% recyclable. Designing for recycling purposes must be mandatory. If no specific regulation is set, the whole thing will not work. When do you expect these specifications to be in place? Dieing: I am very sure that we still have a long way to go. Nothing is likely to change in the short term. This is due to the economic situation we are facing today, and foreign competition, including in mechanical engineering. The technological possibilities are there, but they are expensive. Many customers are simply not prepared to pay the additional costs. In the end, price always wins. What are the benefits of artificial intelligence in plastics recycling? Dieing: I see a huge benefit in this area: in plastics recycling, we have to process large amounts of data extremely quickly in order to optimise processes. AI is exactly the right tool to do this. In the future, there will be more and more specialised applications for AI. Today, we can use cameras and sensors on our conveyor belts in a post-consumer waste stream to identify the manufacturer of a piece of packaging and the material it is made of. With AI, in the future, we will be able to more or less sort in whatever way we wish. For example, we can retrieve data from the internet about a laptop running on the conveyor belt: what processor it has, what components, or how many rare earths have been used. This will offer considerable advantages in the future, because we will be able to sort for value directly from the first material stream. AI also makes material flows safer. Today, we see many recycling plants catching fire because lithium-ion batteries are passing through the shredder. This will no longer happen with the use of AI. What is already possible at Sesotec today? Dieing: We already use AI on our machines to teach them to recognise images, i.e. products. These products are then automatically recognised by every one of our sorters around the world. We also use AI in our sensor technology, which means we can determine with almost 100% certainty whether a product is polyethylene, polypropylene or polystyrene. How will plastics engineering fare in the future? Dieing: Mechanical engineering companies will hold their own. Innovation in Europe remains very strong. Just think how well the new machines are already able to process recycled materials. If we consistently consider recyclability, we will be able to stay ahead of the competition in the future, especially of our competitors in China. However, the Chinese have now learned to build good machines too. We must therefore prepare ourselves for new competitive behaviour from Asia. Basically, though, I am very optimistic about our future. Source VDMA Way2K 2025

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  • "The twin-screw extruder enables high recyclate qualities"

    Interview on the way to K 2025 with Peter von Hoffmann, General Manager Business Unit Compounding Machines, and Frank Lechner, General Manager Process Technology and R&D at Coperion Peter von Hoffmann. Copyright: Coperion GmbH How can resource conservation be improved through greater efficiency in compounding? Peter Von Hoffmann: Efficiency is the central goal at Coperion. All our technologies for compounding and recycling plastics are designed with this goal in mind. One example is our ZSK twin-screw extruder, which we currently offer in the ZSK Mc18 generation. It achieves extremely high throughputs, with relatively low energy consumption and a high degree of automation. Numerous additional units such as side feeding, degassing, and condition monitoring increase its performance, enabling our valuable resources to be used in a highly targeted manner, and maximum output to be achieved with high efficiency. How do you achieve this increase in efficiency? Von Hoffmann: Let's stick with the example of the ZSK extruder: in order to achieve this high power density, all process parameters of the extruder must be correctly determined. The mechanical variables that transfer the high torque to the twin screw need to be specified. In addition, there are process engineering factors that ensure consistently high product quality during compounding. This is the basis: an interplay of "old technology", process engineering and automation. This is where our wealth of experience in the construction of twin-screw extruders really works in our favour. What role does digitalisation play? Von Hoffmann: Once the foundation is in place, digitalisation comes into play. With our CBEYOND digital platform, operators can view the operating data of their plant at any time. This data is available in the form of informative analyses in real time. Important information on key performance indicators (KPIs) for a production line, such as availability, production volume and product quality, is clearly visible at a glance. With C-BEYOND, the production process can be documented in detail, and the scheduling of maintenance work optimised. C-BEYOND also identifies the energy consumption and CO2 emissions per kilogram of compound produced. With the Overall Equipment Effectiveness Tool, or OEE Tool for short, customers can view the efficiency of their plant and react quickly to any deviations. How are digital products of that nature regarded by customers? Von Hoffmann: We initially introduced C-BEYOND to a number of trial customers. Now, increasing numbers of customers want to retrofit their systems with it, in order to benefit from its numerous features. We offer digital life cycle management for example, which provides customers with a proactive maintenance plan that shows when maintenance measures are due for a unit, such as changing the gear oil. We use a condition monitoring system to record the actual load on an extruder. The customer is notified as soon as irregularities occur during an extruder operation and can plan service measures with sufficient lead time. The power consumption of the plant and each unit is also displayed digitally via C-BEYOND. Therefore, anomalies can be identified immediately and countermeasures taken. C-BEYOND can also be viewed on a smartphone via an app. This means that even the company boss can view all the live data from the machines from anywhere. Is there a trend among your customers towards purchasing complete systems? Von Hoffmann: Yes, there is a trend in that direction. At Coperion, we offer everything from individual equipment, such as a feeding unit, a rotary valve, or an extruder, to complete systems. It very much depends on the specific application of the system, and where it is to be installed. We have customers who buy individual units from us. If the systems are intended for other countries, they often want to play it safe and will place an order with us for a complete system. They then benefit from the added value of having a partner who can supply them with everything they need. We have the specialist knowledge for the individual machines, as well as the expertise for complete systems. Frank Lechner. Copyright: Coperion GmbH What role does the twin-screw extruder play in recycling? Frank Lechner: It is key to producing high-quality recycled materials. In the early days of recycling, single-screw extruders were widely used. However, these have limited capabilities and reach those limits when quality requirements increase. This is where the twin-screw extruder is unbeatable, as it melts the waste plastic very energy-efficiently, and produces a very homogeneous, well-degassed melt that is extremely gentle on the product. The result is a very high-quality compound. A second argument in favour of the twin screw is the throughput. A single screw is expedient for lower throughputs, but with material flows becoming larger, and applications more diverse, the twin screw is unbeatable. Has the trend towards recycling slowed down? Lechner: Germany produces around 5.7 million tonnes of plastic waste every year, of which around 35 percent is recycled. There is definitely room for improvement here. However, the demand for recycled materials is currently higher than the availability of raw materials. This is slowing down recycling somewhat. In addition, less plastic is being produced in this country overall because companies have relocated part of their production abroad due to high energy prices. The fact that the oil price is currently quite low is not helpful either. This makes recycled goods significantly more expensive than new goods. Nevertheless, we see a strong drive towards recycling, not only in Germany, but all over the world; that is why we believe that the trend towards recycling is continuing unabatedly. Many plastics are considered non-recyclable. Will that change? Lechner: It's true that we can't recycle everything yet, but there is a lot of research and development taking place. In the future, it will be possible to recycle plastics that are currently considered non-recyclable in an economically viable way. A lot of things are already possible today that weren't possible a few years ago. We are now very good at recycling technical plastics, but also a range of mixed plastics. For example, multi-layer film can already be recycled mechanically in such a way that the result can be reused as a layer in a multi-layer film. With our new ZSK FilCo filtration compounder, we can produce recycled plastic with significantly higher product quality than was previously possible using the common two-stage recycling process. This makes many recompounds attractive for a much wider range of applications. Many companies in Germany are struggling with the problem of a shortage of skilled workers. Is this also your experience at Coperion? Von Hoffmann: The shortage of skilled workers is a major problem for all of us. Due to demographic developments, it is not likely to ease significantly in the foreseeable future. This is one of the reasons why our industry develops machines that are highly automated and therefore require fewer operators. Nevertheless, we will always need qualified personnel. We are working very hard to ensure that we recruit them, and are proud that we are currently training 76 apprentices and dual students at our German sites. We want to attract people to our company at an early stage and retain them. Source VDMA Way2K 2025

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  • "Solution provider Kampf – focusing on people and technology"

    Interview on the way to K 2025 with Markus Vollmer, CEO of Kampf GmbH Markus Vollmer. Copyright: Kampf GmbH Mr Vollmer, Kampf is increasingly evolving from machine manufacturer to solution provider. What does this change mean? Markus Vollmer: We embarked on this path ten years ago, and, in addition, we have significantly accelerated those changes in recent times. We no longer solely offer customers machines but also look at their tasks and goals from their perspective, and then offer the optimal overall solution, including peripherals, and take into account the specialist staff available to the customer. Ultimately, these are complex systems that also consider technical requirements such as digitalisation, connectivity, and, more recently, artificial intelligence. The solution process does not begin with a catalogue from which the customer selects a machine, but with in-depth advice from our experts. Together, we develop a suitable solution. The process only ends when the machine's life cycle ends, sometimes after 20 years or more. Our customers are looking for a state-of-theart machine to be able to adapt throughout its lifetime. How does Kampf design these solutions in concrete terms? Vollmer: We support our customers through every phase of their investment and go far beyond traditional service. Our aim is not only to maintain machines, but also to adapt them in a flexible manner in terms of new legal requirements and ensure our customers' productivity through additional measures such as upgrades, training and consultation. One increasingly important aspect is the qualification of machine operators – in particular through training and refresher courses, which we offer. In the face of increasing staff turnover in many companies, valuable knowledge is often lost. This is where we come in, offering individual solutions tailored to the specific needs of our customers, which are met with a consistently positive response. The customer should be able to focus on their core processes, such as manufacturing films or packaging materials, which is where their expertise lies. They don't need to be machine specialists – that's our job. To ensure that we can do this in the best possible way, we work closely with technology partners, as well as with the customer's operators, shift supervisors and project managers, right from the early stages of a project, when the machine is being designed. Do you also offer adjacent units? Vollmer: Our focus is clearly on the integration of processes in the field of packaging – i.e. the final processing step that usually takes place at the end of production lines and requires closely coordinated processes. We offer complementary solutions for our core process, such as automation, handling systems and other integrated modules. How are you dealing with the shortage of skilled workers at Kampf? Vollmer: We are continuing to do well at Kampf and are still able to find qualified employees. However, we have to be careful not to lose too much knowledge and experience after many of the baby boomer generation retire. We are doing everything we can to make this expertise transparent and available. To this end, we need to improve communication worldwide. We are also proceeding to significantly mixing our interdisciplinary project teams. A mixture of older and younger employees, both experienced and new ones, now make up the teams. We need to pursue this team approach over a longer period of time in order to retain expert knowledge within the company. It is also important to continue to build up expertise. We have been strongly committed to training for many years, and have been able to take on almost all of our apprentices and trainees. We have also set up support programmes for various stakeholder groups and age groups. For example, we have a support programme for young professionals who are accompanied by experienced mentors for two to three years on the job. We also maintain school partnerships to get young people interested in technology and our company as early as possible, and to give them exciting insights into the world of mechanical engineering and automation technology. What are you doing to alleviate your customers' staffing problems? Vollmer: We are developing an intelligent human-machine interface that will enable even non-specialists to operate a machine. At K, we will demonstrate that an untrained person can do this within a short period of time. The machine identifies operators via facial recognition and asks them what tasks they want to carry out. The operator can choose from a range of activities – for example, starting a new cycle or inserting a new roll. They are then guided through the process step by step; no text is used. Instead, videos and 3D animations are provided. In addition, the operator can communicate with our team in the background at any time, as all machines are online. What is the focus at Kampf at the K? Vollmer: We will focus on three areas: in addition to the intelligent AI-supported human-machine interface described above, we will be showcasing larger machines for a wider range of materials that represent a technological leap forward in terms of efficiency. Finally, we will be presenting a new product group for a specific target group – which will be a surprise at the K. Given the current difficult economic environment, K has an important role to play in bringing the industry together. It is still the most international platform where the most innovations are on show. The trade fair will help to provide orientation, and demonstrate the leading position of European mechanical engineering. Source VDMA Way2K 2025

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  • "The use of AI is meant to improve user-friendliness"

    Interview on the way to K 2025 with Timo Horn, Head of Operational Services in Extrusion Technology at Hans Weber Maschinenfabrik GmbH Timo Horn. Copyright: Hans Weber Maschinenfabrik Mr. Horn, to what extent is Hans Weber already relying on artificial intelligence? Timo Horn: Some time ago, we launched a digital customer portal that allows our customers to view operating instructions and create enquiries, among other things. Our next step is to integrate artificial intelligence into this portal, which will make it available to our customers in the near future. This will enable users to address their questions directly to the AI instead of having to search for answers themselves; for example, they can request information on machine maintenance. The aim of this project is to significantly improve user-friendliness. Our customers will be able to access the knowledge provided there and find solutions of their own accord. Where is AI being implemented? Horn: We opted for a browser-based cloud system that can be accessed from any workstation, as not all customers are willing to integrate machines into their internal network. In addition, operators are often not allowed to access other systems via the HMI while the machine is in operation. Our AIsupported customer portal therefore operates on a browser-based system that can be accessed from any workstation. Maintenance managers, operators and shift supervisors can access the web portal from any location and retrieve information about the machines. The AI we have implemented has been specially trained and optimised for the requirements and characteristics of our machines. Are you already thinking about incorporating AI within your machines? Horn: No extruder currently exists that has the ability to control itself and make adjustments independently in the event of deviations. Nevertheless, I am convinced that we will be able to effectively integrate technologies in the field of machine learning in the near future. However, this requires us to gain access to a wide range of comprehensive information and diverse data sources. I am confident that there will soon be a time when machines will be able to take appropriate measures and respond accordingly when an error occurs. The development of AI has gained significant momentum in recent years. What does the future hold? Horn: It is difficult to make a clear prediction - however, significant progress within a very short period of time is certainly conceivable, especially given the latest developments. At the beginning, we were only able to ask our artificial intelligence basic questions. Now, just six months later, it is able to search through extensive documents and analyse transcribed texts effectively. It is reasonable to assume that completely different capabilities will be achievable in another six months. To what extent can AI alleviate the shortage of skilled workers? Horn: The current shortage of skilled labour is a significant challenge for many of our customers. Smallscale companies that have implemented fewer automated processes are often affected to a greater extent compared to larger companies. In this context, artificial intelligence (AI) can be of great benefit: it enables specific questions to be asked, for example regarding maintenance requirements, the optimal time for filter changes, and many other aspects. Of course, this information is also contained in the operating instructions. However, it is more time-saving to consult AI to obtain the desired information. In view of the demographic change, we are all confronted with the fundamental problem of the loss of expertise, which can only be mitigated to a limited extent at corporate level. I am convinced that many companies will strive to further digitise, automate and optimise their processes in order to proactively counteract the shortage of skilled workers. Skilled workers will continue to be needed, but with the help of AI, it will also be possible to entrust people with the operation of complex machines, without extensive machine knowledge. What is Hans Weber doing in terms of sustainability? Horn: One outstanding feature of our company is our very high vertical range of manufacture. This enables us to supply our machines with high-quality spare parts for decades. In addition, we develop our control systems in-house, enabling us to update them comprehensively. If a customer owns a 20-year-old machine and wants to collect data as part of digitalisation measures, we can offer them a tailor-made retrofit package for our modern WEBER OS5 control system. This package can be installed by the customer themselves or by our qualified technicians, allowing us to offer our customers the opportunity to reach a new level of technology. In addition to modernising control systems, we also support the retrofitting of innovative and efficient drive systems in three-phase technology. This provides our customers with the opportunity to even enhance older machines to be state of the art, thereby increasing their competitive edge in the long run. Where does mechanical engineering currently stand in terms of digitalisation? Horn: Digitalisation plays a central role in mechanical engineering. In future, it will be essential to have a digital presence. The implementation of digital solutions will increase efficiency in production and throughout the entire process, enabling production processes to be precisely controlled. The data collected can be used to track how long machines are in operation, and whether they are running smoothly. This data can be used to make well-founded decisions. For example, if a shift supervisor is responsible for several machines and notices that processes are not running optimally, they have to rely on information from the operators. However, if they have additional data, they can immediately see whether there are pressure fluctuations, profile breaks, or other irregularities. This enables them to make more reliable decisions to optimise processes. In addition, this digital transformation phase opens up new perspectives for us as a machine manufacturer for the development of innovative business models. Based on the data obtained, we are able to offer new services to our customers. For machine builders, digitalisation is therefore not an optional trend, but a key driver for the future viability, innovation and competitiveness of our industry. Source VDMA Way2K 2025

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  • "The pressure is on to recycle post-production waste"

    Interview on the way to K 2025 with Patrick Henzler, Sales Director at WEIMA Maschinenbau Patrick Henzler. Copyright: WEIMA Mr. Henzler, how is post-consumer recycling developing in the market? Patrick Henzler: Post-consumer recycling has been under severe pressure in Europe for around two years. Many of our customers in this sector are relocating production to more cost-effective foreign countries or closing their operations completely after 20 or even 30 years. Recyclers who work in the post-consumer sector have high requirements for the treatment of the material. The materials are contaminated; they have to be washed and sometimes sorted – even if they are purchased from a sorting plant. This results in high energy consumption and therefore high costs in Germany. Added to this is the lack of well-trained personnel. Finally, recyclers in Germany are being hit by the flow of cheap recycling material from Asia, especially from China. This material is produced under different market conditions: the personnel requirements are lower, as are labour and energy overheads. Are things looking better for post-production recycling? Henzler: Yes, the situation is fundamentally different there. If someone manufactures pipes for example, they have their own production waste. This waste is clean. It doesn't incur the same high costs as post-consumer waste. Another positive aspect is that you have control over your own waste stream. It is true that this area is currently developing more slowly than before; not for structural reasons, but because of the sluggish global economy. Projects are often being postponed at the moment, but they are not being cancelled. There is pressure to recycle post-production waste. The aim is to avoid disposal costs for example. Companies would rather invest in a recycling solution than having to cope with high logistics costs every month. For us as a machine manufacturer, both areas are very important. What do you at WEIMA think of the trend towards system integration? Henzler: This is an existing trend. Many customers want to buy all the components of a new system from a single source. They want to hand over responsibility for smooth production to a system provider. However, this can mean that they will need to make compromises, because not every machine in a system necessarily has to be the best of its kind. We do not go along with this trend and instead follow the motto to "stick with what you know". We are convinced that if you attempt to do everything, you’ll end up not doing things well enough. We know our products, but we are also adding new products and developing them further. For example, we have taken over a company that manufactures dewatering presses. In the past, these were mainly used in the food sector. We have now further developed this dewatering press so that it can also be used in carwash units. At the end of the system there is one of our classic shredding machines. This is an increase in efficiency for us. How does WEIMA contribute to solving the shortage of skilled workers? Henzler: We enable our customers to deploy their personnel efficiently on our machines, whereby the key word is ease of maintenance. Customers want to carry out the necessary machine maintenance as quickly as possible and are increasingly looking to switch to machine monitoring. This is because the shortage of maintenance personnel is already at a concerning level throughout Europe, and will continue to increase. We have developed a special tool, the WE.monitor, which detects faults and also enables automatic countermeasures to be taken, thereby simplifying and optimizing maintenance. Customers spend a considerable amount of money on a machine, so they ask us to develop the machines in such a way that dependency on personnel is as limited as possible. What contribution does WEIMA make towards sustainability? Henzler: WEIMA attaches great importance to it as a company. For example, we have equipped all of our production hall roofs with solar panels and supply our own electricity. In terms of our products, we contribute towards sustainability through high energy efficiency. Our machines consume a minor amount of electricity and can process materials in a way that conserves resources. However, the recycling requirements in Europe are very strict, which leads to high costs; something that competitors elsewhere do not have to contend with. In many countries, the processing water from a car wash is simply discharged into the nearest river. However, the greater the awareness of sustainable business practices in these countries, the greater the opportunity for European machine manufacturers to play a pioneering role there. What does WEIMA expect from the K? Henzler: We are quite optimistic and therefore expect a number of enquiries despite the aforementioned problems in the post-consumer sector. These affect Europe and the USA, but we must not forget that the markets in Asia are growth markets. The world is not homogeneous, and an international company like ours always has the advantage of balancing its business across the different regions of the world. We also expect new enquiries in the field of post-industrial recycling at K. In general, we expect fewer business deals than at previous trade fairs. Many companies tend to wait and realize a planned project one or two years later. Source VDMA Way2K 2025

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  • "The circular economy will only succeed if we develop collectively across the entire value chain"

    Interview on the road to K 2025 with Manfred Hackl, CEO of the EREMA Group Manfred Hackl. Copyright: EREMA Group Mr. Hackl, EREMA celebrated its 40th anniversary in 2023. How has recycling developed during that time? Manfred Hackl: If you look back over these 40 years, you will realise that an incredible amount has been achieved in plastics recycling. Today it is technologically possible to do things that we could not have imagined 40 years ago, 20 years ago or even 5 years ago. Recycling technologies have developed rapidly. As EREMA, we have repeatedly set milestones and have always been a driver of innovation. At this year's K, we will once again be presenting many new products, especially solutions that further improve recyclate quality. Can you give a few examples of the developments? Hackl: In 2016, the circular economy made its first big appearance at the K fair. A lot has happened since then. Nine years ago, for example, there was no rHDPE packaging for food contact, and no household bottles or body care bottles made from post-consumer material. Supermarket film with recycled content was still quite a way off back then. All of these now exist, which shows how fast everything has developed. However, this process must of course continue. The interaction of innovative solutions is still needed to drive plastic recycling forward: the right washing method with the right extrusion, with the right filtration to produce regranulate of the highest quality and odour neutrality. We have the precise technology to ensure this through our group of companies; however, the circular economy will basically only progress if we develop together across the entire plastics value chain. The current economic environment doesn’t look promising. What is the situation in your sector? Hackl: The recent economic situation of many companies within our industry has not developed very satisfactorily, due to the fact that numerous geopolitical upheavals have made customers reluctant to invest. We all hope that the K will have a positive effect on generating business for companies. I am encouraged by the fact that the EU's Clean Industrial Deal and the Green Deal are very much focused on the circular economy. We are also noticing that the major brand manufacturers and consumers now want to keep materials within the plastics cycle. What is the logic behind the cooperation between EREMA and Lindner? Hackl: It is actually more than just a cooperation. We have jointly founded the Blueone Solutions holding company, in which EREMA and Lindner each hold 50 percent of the shares. We are now a group of companies. Through the joint venture, we are creating a digitalized and industrialised process from waste to the finished pellet. At K, we will be presenting new solutions and demonstrating that we need to think holistically if we want to achieve the next level of recyclate quality. What needs to happen for recycling to be economical in the long term? Hackl: The cost-effectiveness of recycling always depends on the price of virgin material. If the price is low, as is currently the case, recycling is more expensive. Comprehensive countermeasures are needed here so that long-term planning is possible. How are you supposed to make a plant that has been depreciating over five or ten years economically viable if you have to purchase your input, your raw material, at monthly prices, as is the case today? Instead of a plastics tax, a CO₂ bonus for the regranulate would be desirable. If the positive CO₂ contribution of recycled pellets – which is 25 to 30 percent depending on the application – was taken into account accordingly, this could contribute to the urgently needed price stability; both would be effective measures. Can they be implemented in practice? Hackl: I am convinced that something has to be done if we want to promote the circular economy. The whole thing should be initiated by the EU. Then it is quite possible that others will follow suit. Countries such as India, China, America and many others have already adapted their legislation in the area of the circular economy to comply with EU regulations. They have recognized that the circular economy conserves valuable resources. In my view, the EU should once again take on a pioneering role and introduce models such as those just mentioned. We would then have a good chance of being a role model in Europe again. What are you planning for the K? Hackl: As usual, we will be presenting technological innovations at K. We will also be running live recycling together with Lindner in the outdoor area. As a group of companies, we will be presenting solutions along the entire process chain. As the largest company in the Group, EREMA will be at the centre of our trade fair presence with a broad portfolio for a wide range of applications, which we are expanding with new technologies at K. Under the campaign title "Edvanced Recycling - EREMA Prime Solutions for Advanced Recycling", we are getting to the heart of what sets EREMA apart: many years of experience combined with practical application expertise and advanced recycling solutions. The chosen spelling makes it clear that modern recycling is undoubtedly associated with EREMA. Edvanced Recycling makes visible how EREMA, together with our customers, sustainably increases the proportion of recycled material in plastic products. Source VDMA Way2K 2025

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  • "Local solutions to global challenges"

    Interview on the road to K 2025 with Carl Litherland, CMO of the motan Group Carl Litherland; Copyright: motan Gruppe Mr. Litherland, what is the current overall economic situation for motan? Carl Litherland: The global economic conditions have changed noticeably in the years since the last K. Global supply chains are under increasing pressure, and the trend towards deglobalisation – particularly as a result of new trade policy measures by the USA – is presenting many companies with new challenges. Rising customs duties and logistic costs are not only placing a strain on us, but also on our customers. We began adapting our structures to this changed situation at an early stage. Even though our roots lie in the German SME sector, we are consistently developing into a decentralised, internationally active group. In addition to our existing operation centres in Germany and China, we have recently opened one in India. It is not just a matter of sales and service, but also specifically of local production, with regional staff and regional supply chains, which allows us to generate a more flexible response to market requirements, overcome regulatory hurdles more effectively, and position ourselves more efficiently within the local competitive environment. An additional advantage is that shorter transportation routes reduce the burden on the environment and contribute towards more sustainable value creation. Our decentralised strategy is therefore not only an economically necessary response to global developments, but also a contribution towards greater ecological responsibility. How is motan responding to the economic difficulties facing customers? Litherland: Many of our customers – particularly in Europe – are currently under considerable economic pressure. A fast, reliable solution is particularly in demand in such phases. This is precisely where our swift line comes in. We offer our customers standardised products with short delivery times, without the need for individual customisation, but with the usual quality, functionality and user-friendliness. Our core business remains the development of customised systems for complex applications. However, in injection moulding in particular, many standard applications – which account for more than 50 percent – can be efficiently covered with swift. This allows us to offer our customers an economically viable solution without compromising on technology. Our swift line is ideal for fast-growing markets such as India, Africa, Eastern Europe or South America, where requirements are different from those in established markets. This allows us to act in a targeted and competitive manner in these markets and provide the right solutions for our customers' needs. What role does plastic play as a material in the current market situation? Litherland: Plastic is still a key material, for example in medical technology. At the same time, awareness of more sustainable solutions is growing. Mono-materials, which are easier to recycle, are becoming more important and recyclates are increasingly being used. This also places new demands on our technology: drying, dosing, mixing and conveying are becoming more complex, as recyclates often have fluctuating qualities. Our task is to enable stable processes even under these conditions. At the same time, economic efficiency remains crucial. Due to the current low raw material prices, many customers are once again turning to virgin material more frequently. Plastic will remain, but how we deal with it will change, and this is precisely where we are supporting our customers through suitable solutions. Are technical problems a thing of the past? Litherland: The basic requirements have not changed much, but the solutions have. Recycled materials often involve material fluctuations – especially in terms of residual moisture, which must be reliably monitored at all times. It is important to be able to clearly assess the tolerance range within which we are operating, such as what the dryer and what the injection moulding machine can make up for. Fast response times are required here, and this is precisely where digitalisation provides valuable support. It enables more transparency, improved process monitoring, and significantly greater stability during operation. How does the motan foundation help to promote social responsibility in the plastics industry? Litherland: The motan Foundation was established with the clear aim of assuming social responsibility in the use of plastics. Its focus is on projects that deal with the sensible handling of plastic after its initial use – ideally with its return to the circular economy in order to minimise environmental impact. Many of the funded initiatives take place in economically weaker or emerging countries. This is because the greatest ecological damage is often caused in these regions, while the economic benefits from plastic products remain predominantly in the industrialised nations. This is where the foundation comes in, with educational work and very specific aid projects. For example: in Cambodia, a small truck was donated to improve waste collection and recycling on site. Such projects are also met with a great response within our company, and many employees contribute their own ideas. Our aim is to promote commitment, because every contribution counts when it comes to gradually solving global challenges. Source VDMA Way2K 2025

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  • "Operator support is becoming increasingly important"

    Interview on the road to K 2025 with Dr. Henning Stieglitz, CEO and CTO at BC Extrusion Holding GmbH Dr. Henning Stieglitz. Copyright: Battenfeld-Cincinnati Dr. Stieglitz, where can efficiencies still be improved in plastics extrusion? Dr. Henning Stieglitz: There are four key factors for us: the use of materials, the line speed, the use of energy and the use of recyclates. The biggest driver is the use of materials. This is also the focus of our research. The aim is to keep the tolerances as low as possible so that the customer can go to the lowest limit, and at the same time achieve the highest savings in terms of materials. The ideal scenario would be to get 100 kg of pipe or window profile from 100 kg of material. As a rule, you always have to use a little more, either because the changeover time requires the use of material, the material properties do not allow it, or you reach the limits of the tools. The use of recyclate is a comparatively recent topic and depends heavily on the type of application. Large quantities have been used in the window profile sector for a long time. It is slowly gaining momentum in the pipe sector, and the use of recyclate has also been increasing in the packaging sector for years. Is it difficult to minimise the use of materials and at the same time use recycled materials? Stieglitz: Yes, because the properties of recycled materials are generally not as consistent as those of virgin material. This is an issue we have been increasingly addressing in recent years: how customers can manufacture the best possible product from post-consumer material – using as little material as possible and, of course, with as little energy as possible. This is a challenge that has become increasingly important everywhere over the past few years, and one that we are increasingly focusing on in our machine concepts. Are you already using artificial intelligence? Stieglitz: Battenfeld-cincinnati would like to use AI in particular to support operators and make their daily operations easier. We have realised that the qualification requirements have increased over the years, and we can specifically support the operators in their daily operations: for instance, an AI that tells the operator when an error occurs, what the cause is, and how it can be rectified – or that shows that the operational energy consumption is not optimal, and makes suggestions on how to improve it. To do this, you have to record certain error types, and store corrective measures that can then be retrieved from the system. This operator support is becoming increasingly important. We are endeavouring to provide systems that are very easy to use and very supportive. To do this, we will need to utilise AI. Is this a step towards the "unmanned machine"? Stieglitz: Absolutely. Our Fast Dimension Change (FDC) system, for example, makes it possible to adjust the dimension of a pipe during operation with the help of the control unit and its built-in components. In principle, there are memorised recipes: you press a button, and the system changes the wall thickness and pipe diameter. This works without anyone having to intervene manually. Only one person is needed to make the change on the control unit. The machine does the rest. There is something similar for simple tasks in production. I can't say whether there will ever be a fully automated line. There will certainly always have to be a supervisor, but many other tasks will be automated. Has the circular economy taken a back seat in the face of economic problems? Stieglitz: When the circular economy was on everyone's lips a few years ago, people would have preferred everything to be made from 100 percent recycled materials. Back then, too little consideration was often given to the cost aspect. Things are different today. It is still the case that using post-consumer materials generally costs more than using new materials. You have to ask yourself who is going to pay the additional costs in the end. There are already very good solutions for recycling. For PET bottles, the cycle in Germany is almost closed. I would like to see a similarly solid system established for two or three other mass plastics. In some respects, however, we have overshot the mark. It is important to come to a reasonable understanding: What really makes sense, and in which instances does recycling not make sense? Coated paper has recently been heavily promoted as a packaging material in some areas. The paper used here is extremely highly processed, and the composite is almost impossible to recycle. Could the circular economy become an export hit? Stieglitz: Well, it won’t be everywhere, it's simply a matter of cost. If it is already difficult to pass on the higher costs of recycling to the products here, then how would that be possible in developing countries? The priorities there are different. The aim in those countries is to ensure that all people have access to food, and that food does not go to waste during transportation. For this reason, there will probably not be a complete cycle for post-consumer plastics there in the foreseeable future. However, it will be possible to tackle individual aspects of the circular economy, such as collection systems for example. Even the controlled combustion of the waste, including energy generation, would then be a comparatively smaller burden, and at least would not be contributing towards increasing the waste problem in the oceans. What do you expect from the upcoming K? Stieglitz: I am sure that K will be very well attended. Our industry has had some difficult years recently, but we must not forget that 2021 and 2022 were very good. I expect more clarity on the future tariff agreements with the US by October. After all, uncertainty about what will happen next is worse than tariffs; it slows down investment. I think that once the uncertainty has subsided, visitors will want to see new things again, innovations that people will want to invest in. In addition to digitalisation in general, I expect topics such as operator support via the control system to be a focus, plus of course the efficient use of resources. Source VDMA Way2K 2025

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