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)

  • "You can't please the whole world from Germany"

    Interview on the way to K 2025 with Andrea Carta, Moulding Machines Managing Director at Kurtz Ersa Andrea Carta. Copyright: Kurtz Ersa Mr. Carta, as a medium-sized company, what strategies do you utilise to identify long-term growth potential despite economic challenges? Andrea Carta: The Kurtz family and management have ensured the consolidation of the Group through three pillars that also work independently of each other: Electronics Production Equipment, Moulding Machines, and Automation. We are constantly looking to expand these business areas, and are always asking ourselves whether – and in which area – we should perhaps establish a fourth pillar. It is extremely important for us not to be dependent on one single business or sector. Although there are many joint projects between our three divisions, each division runs its business independently. How important is it to be close to customers, especially in the current situation? Carta: In view of the many multinational crises of the recent past, over the last years, we have been putting a lot of effort into expanding our global footprint. We established our own production sites outside Germany at an early stage – in the USA, China, and in Mexico last year. Due to the fact that manufacturing takes place there, we are less susceptible to customs duties. Apart from the geopolitical advantages, I have always been of the opinion that you can't please the whole world from Germany. Customer requirements differ from country to country. That is why it is important to be very close to customers, in order to better recognise and meet their requirements. For example, if the level of automation in a country is still low, we have to offer machines there that are operated by more staff than it would be the case in countries with a high level of automation. It is incredibly important to match the right products to the respective markets. As a medium-sized company, Kurtz has been doing this for a long time. In my view, this is exemplary. How important is resource conservation in the various markets? Carta: We have already come a long way in Europe. Strong regulations here require that many products and processes are being developed that benefit the environment and sustainability. This is also an advantage over our competitors, because if you don't set these requirements, you won't incorporate them into your products. Sustainability is now highly valued in China. For us as a mechanical engineering company, China is therefore a market for sustainable solutions. I consider Japan and Korea to be on roughly the same level as Europe. Southeast Asia is not yet as advanced. In South America, the idea of resource conservation is still in its infancy. I view current developments in the USA as problematic, as politics are very erratic, depending on which president is in office at the time. This creates great uncertainty regarding the extent to which they are focusing on sustainability. How can greater efficiency help to reduce the use of plastics? Carta: The key to greater efficiency is the process. This is where we are leaders in the German plastics machinery industry. We know the complexity of the processes and we are able to handle them. Understanding the process and having the right machines brings two major advantages: firstly, the precise use of material already offers efficiency benefits. At the next K trade fair, we at Kurtz will be presenting a new dosing system that is so precise that it can save five to ten percent of materials. Secondly, we have processes in place that ensure that less waste is being produced. These are the two levers. As far as the processes are concerned, we are still much further ahead of the Chinese. What is the current status of the circular economy? Carta: The circular economy is a process that will take a long time. European mechanical engineering has only just started. I think we have to give mechanical engineering the chance to develop the necessary processes. I don't see the goal as being to recycle 100 percent of used plastics. I see it from a business perspective: Germany is further ahead of everyone else. We have a unique selling point here and we should use it to generate further business. Will everyone join in? No, not everyone will be joining in. There are a lot of countries that still do not recycle at all, but many other countries are continuing to increase their recycling levels. I believe that the circular economy needs further encouragement and requirements. We are on the right track, both in terms of the environment and industry. We are developing a lot of technologies – because we are leading the way, which will benefit our business on a global scale. What potential does artificial intelligence have? Carta: AI will have a huge impact on our business. Our machines generate billions of data over their life cycle, which is what AI requires in order to learn. With the help of AI for example, we will be able to produce and process recyclates better. AI will learn which material fluctuation should be treated and how. You could argue that the process sovereignty that we have in Germany would no longer be necessary; that is only superficially true. In order to maintain process sovereignty, we have to invest more than everyone else, and need to make our machines AI-capable as quickly as possible; otherwise other parties will be faster, and it will be too late for us. The motto of the K is very self-confident: "The Power of Plastics". What does this power consist of? Carta: Plastics have made the world a better place and will make it even better in the future. No material in the past has achieved what plastics make possible – except perhaps metal. Plastics form the basis for the quality of life to which we have become accustomed. The world would be unthinkable without plastics. They have disadvantages, just like any other material. Is everything good that is made from plastics? No, it is not. But in some areas it is the best possible material. Should we use less plastic packaging? Probably, yes. But fundamentally, plastics are extremely valuable. That's why I think the K's self-confident motto is very good. Source VDMA Way2K 2025

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  • "The quality of the recyclate is crucial"

    Interview on the way to K 2025 with Thorsten Jacoby, Managing Director of Erlenbach GmbH, part of the hetech group Thorsten Jacoby; Copyright: Erlenbach GmbH Mr. Jacoby, how does Erlenbach contribute towards resource conservation and sustainability? Thorsten Jacoby: As a medium-sized mechanical engineering company specialising in processing technologies for particle foams, we are making a significant contribution towards resource conservation and sustainability. Firstly, by continuously increasing efficiency to minimise energy consumption in the processing of particle foams. The use of these energy-efficient technologies also reduces the CO2 footprint of the products manufactured on these systems. In addition, EPS and EPP, for example, are highly recyclable. If the material is unmixed and only slightly contaminated, a recycling rate of almost 100 percent is possible. Finally, bio-based particle foams can also be produced using systems from the hetech group, of which Erlenbach is a part. Because the material is renewable, the CO2 footprint is even smaller in this respect. What requirements are necessary to achieve high recyclate quality? Jacoby: The quality depends to a large extent on the purity of the variety on the one hand, and the recycling process on the other; there are already many technical possibilities available. The upstream processes of sorting and cleaning are also quite mature. In the end however, it is also a question of economic efficiency. All these process steps are cost-intensive, and if the price of virgin material is low, the production and processing of recyclate is not worthwhile. In any case, it is important to handle raw materials carefully when using them, for example: plastic waste is already being collected on construction sites, but rubbish bags contain insulation boards made of EPS, some of which are heavily contaminated. Additional sorting equipment is then required to separate the materials. However, it would be much better if the contaminants were not present within the boards in the first place. Product handling is the decisive factor, and these would then have to be designed in such a way that printed material or adhesives, for example, can be removed very easily. People are not yet very aware of the need to do things properly when collecting. By contrast, EPS packaging for example can be very easily recycled in a single-sort collection. Where are we on the road to a circular economy for plastics? Jacoby: Much is already possible in terms of plant technology, but there is still room for further optimisation. Recycling is already taking place. There are many efforts in the market to better organise and structure collection processes. Processors are often aware of the importance of recycling, but implementation also depends on the customers, some of whom still specify virgin material. What can you do in this situation? Jacoby: It is important to raise awareness that a recycled product can fulfil the same requirements as one made from virgin material if it is of the same quality. The quality of the recycled material is crucial. One way of guaranteeing this quality would be to have uniform standards for recyclates. Processors would then always know exactly what material they order and receive. This would increase the acceptance of recyclate, and products made from recyclate, and this would also increase their use. Is the plastics industry still struggling with its image? Jacoby: There are calls for a plastic-free world. What nonsense! It is impossible to imagine our modern world without plastic. The question is how to deal with plastics that are recyclable, and to what extent they should be recycled. There are many good approaches in the actual process, but also in higher-level processes. For example, we can already produce an rEPS from an EPS and process it in the same process. One major challenge is collecting the material so that it can be used again in the same processing method. What role does chemical recycling play? Jacoby: All available possibilities of the circular economy are required in order to close all loops and produce high-quality raw materials. This also includes chemical recycling for those fractions that are not suitable for lower-threshold recycling, for example mechanical recycling. This allows the original raw materials to be recovered. In principle, the original monomer is turned back into PS and EPS. However, chemical recycling is a very complex process with correspondingly high costs. What can K do to push the circular economy? Jacoby: K continues to be one of the world's most important trade fairs for plastics and rubber. It can therefore play a key role in promoting sustainable solutions such as the circular economy and help to make them more marketable. K is a major technology and innovation platform, where all renowned manufacturers from every region present their latest developments, and plant technologies, as well as all of the raw material manufacturers who are present with their newest innovations. This naturally promotes the exchange of best practices and also creates new ideas for the circular economy. Source VDMA Way2K 2025

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  • "Plastic is simply indispensable as a material"

    Interview on the road to K 2025 with Dr. Christoph Schumacher, Vice President Global Marketing at Arburg GmbH + Co KG Christoph Schumacher; Copyright: Arburg GmbH + Co KG Dr. Schumacher, the next K is being held under the motto ‘The Power of Plastics – Green – Smart – Responsible’. How did this motto come about? Dr. Christoph Schumacher: It is basically the result of a lengthy development process. The realisation that solving sustainability issues is becoming increasingly important and urgent was first expressed openly while preparing for K 2019. At that time, the initial focus was on raising awareness, and a common understanding of the issue was established within the industry. Keywords such as circular economy came to the fore. At K 2022, for the first time, plastics machinery manufacturers then presented all the solutions that were available, for example in the field of recycling, on a large scale. There was a special VDMA show where Arburg also took part and had their own stand. At K 2025, we now want to emphasise the strength and ability to shape the future of both plastic materials and the industry in all its facets - hence the absolutely self-confident – and, in my opinion, truly meaningful – motto. What message are you trying to convey? Schumacher: We want to make it clear that we understand the social topicality of the issue, while at the same time wanting to show that the German-speaking mechanical and plant engineering industry can make an outstanding contribution towards solving the problems. In this context, I’ve always particularly liked the term ‘enabler’, for example, by providing technologies that enable the circular economy. In doing so, it helps to go easy on resources, while at the same time managing targeted multiple usage. In my view, there are very few industries that are addressing these social and ecological issues as extensively as the plastics processing industry has been doing for years. At the same time, we want to emphasise that plastic is simply indispensable as a material. It is needed to reduce CO2, and it is vital for e-mobility, lightweight construction, medicine, and for packaging. During the Covid pandemic, we witnessed that anything that was not protected by plastic could simply be life-threatening. At that time, perhaps we did not make enough use of this shift in sentiment as an industry. We assume the responsibility to deal a lot more with recycling. ‘Power of Plastics’ shows our conviction that modern life will not be possible without plastic in the future. And what about ‘Green – Smart – Responsible’? Schumacher: These three dimensions show where this power comes from. ‘Green’ stands for the paths that lead to greater sustainability. ‘Smart’ refers to the technologies that can be used, for example, within the context of digitalisation. ‘Responsible’ describes social responsibility in general, but also the fact that we are tackling the quantitative and qualitative problem of recruiting skilled workers. Our customers expect us, as a mechanical and plant engineering company, to find a solution to this task: to manufacture increasingly complex products with increasingly complex machines, with decreasingly complex staff skill set demands. To what extent does the K motto suit Arburg? Schumacher: It suits Arburg very well in all three dimensions, as they have long been the genetic makeup of our company, so to speak. We bundled the issues of sustainability many years ago in our arburgGREENworld programme, and the issues of digitalisation in a programme called arburgXworld. And we are bringing them together in the arburgSOLUTIONworld: a range of solutions for all our customers' needs. In addition, there are numerous collaborations with initiatives such as R-Cycle, or with start-ups in the field of materials. Responsibility is in the nature of our company because, at our location in rural Lossburg, we have always relied on the responsible use of resources and good interaction with our employees. Is a green, intelligent and responsible plastics engineering industry also a viable business model? Schumacher: I can say for sure that solving the issues in question is a good business model for German-speaking injection moulding machine manufacturers. These solutions can be exported all over the world, and we can make money from them. Many of our competitors, especially in Asia, cannot keep up. On the other hand, the markets in Asia are the fastest growing ones. Sustainable machine technology will also be needed there; these are precisely the opportunities that the business model offers. What does the future hold for plastics machinery manufacturing? Schumacher: The plastics machinery industry will continue to develop very well. For almost 100 years, this industry has repeatedly proven that it is adaptable and can develop solutions for upcoming tasks. It is this enabler role that distinguishes it. Moreover, the opportunities offered by plastic as a material have not yet been fully exploited or even recognised. I strongly believe that modern life is inconceivable without plastic for increasing numbers of people all across the globe. However, the disposal, recycling, design and styling of plastic products, as well as material savings and the most sensible use of this material, are areas within which there is still a lot to be done. I am therefore convinced that in ten years, plastics processing will no longer be feasible without a circular economy system. Source VDMA Way2K 2025

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  • "Efficiency is the driver of the plastics industry"

    Interview on the way to K 2025 with Jörg Stech, Chairman of the Management Board at KraussMaffei Technologies Jörg Stech; Copyright: KraussMaffei Mr. Stech, what are today’s plastics industry drivers? Jörg Stech: Profitability and efficiency continue to be the main drivers of the plastics industry. When customers manufacture plastic parts, they usually do so in large quantities. Customers' technological demands are increasing, led by the motto: faster, more powerful and, above all, more efficient. For us as a manufacturer, this means developing technologies and processes that are better, more efficient and therefore more economical than those of our competitors. Other drivers are the new applications and products on the market. Let's take cars for example: in vehicles with combustion engines, many components in the engine compartment are made of metal so that the generated heat can be dissipated. With electric cars, new requirements arise due to their different design; on the one hand, it affects the material that the components are made of while on the other hand, completely newcomponents are required. For example, it is possible to manufacture some components for electric motors from plastic, as there is no longer any functional need for heat dissipation. The components themselves also fulfil other functions nowadays. Whereas in the past, they used to be mechanically necessary, today they are sometimes purely design elements. The plastics industry is also being driven by new regulations. The EU has set itself the target that at least 25 percent of plastic parts in new cars should consist of recycled plastic by 2030 for example. It is our task to find solutions that are able to fulfil this target. Can you provide an example? Stech: Let's take a look at the automotive industry again: if a bonnet no longer needs to be produced of metal for functional reasons, then it can also be made of plastic, meaning KraussMaffei produces it economically using injection moulding technology. And not only that – it can even be painted directly in the injection moulding machine using our ColorForm process. This makes separate painting systems and transport routes obsolete. Production is becoming more efficient, and the entire industry is gradually changing, resulting in new opportunities. Even if the conditions on the global competitive market have changed and become more difficult, this opens up opportunities for German machine manufacturers, especially for us in injection moulding technology, to develop new technologies in line with new customer requirements. What role does innovation play in your organisation? Stech: Without innovation, Europe will find itself struggling to compete in the global marketplace. It is a fact that we are more expensive than our competitors in the Far East, for example, because we have higher production costs, as well as personnel and energy overheads, and logistics costs for national and international sourcing are also an essential factor. That is why we are clearly focusing on the development of innovations and new technologies. Our aim is to offer the customer a product that goes far beyond that of a standard injection moulding machine. In the production of injection moulded parts for example, one issue is reducing energy requirements, which enables savings. However, we also use technologies that lead to a reduction in the material usage rate, or that allow other materials to be used, such as recycled material. These are all technologies that we need to develop further. How is this achieved? Stech: Innovation does not always mean a new invention - rather, we see the potential in small innovative steps, for example by way of consistent further development of existing processes. In doing so, we deal with various questions: How can the fibre content be increased? How can we influence key parameters of the injection moulding process? Is it possible to injection mould a component at lower temperatures? To sum it up, these factors have a huge impact. Expertise and direct exchange with the customer are our competitive advantage, as they cannot simply be purchased as a sample solution on the world market. The demand-oriented production of injection moulding machines, including the development of customer-specific applications, goes far beyond standard injection moulding machine construction. Thanks to cooperative collaboration and development, we are able to generate the highest possible added value for our customers. We benefit from the fact that we can draw on the entire KraussMaffei know-how of our various technologies, from injection moulding and reaction process machinery to additive manufacturing, automation and extrusion. What role will skilled workers and suitable new recruits play? Stech: Of course, we need top talents with specific knowledge for our tasks. No matter what position we need to fill, we have to attract the specialists to KraussMaffei. Unfortunately, we often aren’t able to find these specialists locally. But we benefit from the attractiveness of Munich as a location in general and from our new plant in Parsdorf. Investments in the new factory and office buildings, machines, and our technical centre have increased KraussMaffei's appeal on the labour market, but also among the core team on site. It has created conditions that enable our colleagues to work well and generate new solutions. Every individual counts, because innovation comes from everyone – from sales staff to machine operators. We also attach great importance to education in the sense of further and advanced training. With the development of our LearningPods, learning cabins that can be set up anywhere, employees can learn specific procedures or acquire relevant knowledge by means of short video clips. The LearningPods are particularly suitable for employees who either do not have a fixed computer workstation or work in production. This product is so attractive that it is also sold to other companies where employee training is equally important. Where does Europe currently stand in terms of sustainability? Stech: The EU is currently the driving force behind sustainability. This is a good thing, because if Europe did not drive sustainability forward, the world as a whole would be much less concerned with it. KraussMaffei is therefore intensively searching for more sustainable solutions to ensure that later generations have a decent future. It is essential that the rules that lead to resource preservation and a better use of plastic apply equally to everyone, regardless of which industry or country they affect. If European regulations lead to a situation where only European manufacturers are at a disadvantage, this will further penalise and weaken Europe's economic situation, something that is not acceptable. We need systems that will ensure fair competition for all. Source VDMA Way2K 2025

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  • "We are still at the beginning of the circular economy in many areas"

    Interview on the way to K 2025 with Sebastian Rust, Managing Director at ENTEX Sebastian Rust; Copyright: ENTEX Mr. Rust, what are the advantages of the planetary roller extruder for recycling plastics? Sebastian Rust: The plastics that are recycled have all experienced thermal damage at some point. They have been subjected to massive stress. Our system has the advantage that we introduce very little mechanical energy into the extrudate. With twin-screw and single-screw extruders, the material is mainly plasticised by way of the mechanical energy input of the main drive. We, by contrast, melt the material in the planetary roller extruder by means of thermal energy input, which is gentle on the material. As a result, we never actually need the full drive power of the extruder, and energy consumption is correspondingly lower. This saves considerable costs, and ultimately also reduces the CO2 footprint. Another contribution to sustainability would be the devulcanization of used tyres. Where does ENTEX stand in this respect? Rust: Recycling used tyres was long considered technically impossible. Used tyres, regardless of the type of vehicle, are recycled thermally these days. For example, they are used as fuel for generating energy in cement works. At ENTEX, we have played a major role in shaping the devulcanization process and have now reached a point where we are able to separate the carbon chains from the sulphur chains through targeted energy input, thereby reversing the vulcanisation process. This enables us to recover most of the natural rubber, which can then be reused as a recyclate in new tyres, as well as a wide range of other rubber applications. So basically, the era of used tyre recycling has already begun? Rust: The tyre industry is very conservative and likes to stick to established and traditional process chains. In tyre production, the recipes are often very old. Every minor change to a tyre composition always entails a change in production and a great deal of effort, which is why it is not so easy to implement innovations. However, this is likely to change in the foreseeable future. Politicians are exerting pressure and stipulating that new products must contain a certain proportion of recycled material in the near future. This will make the whole issue increasingly interesting for us. Ultimately, we have to develop further, and we therefore hope that new technologies, such as devulcanization, can become an established part of the transformation towards a circular economy. Can a new tyre be made from 100 percent recycled material? Rust: It is a realistic assumption that in future, it will be possible to add 40 to 50 percent of devulcanized recyclate to natural rubber. There are already a number of studies and trials in this field, which all look very promising. Where do we stand in the circular economy today? Rust: In my view, we are still at the beginning in many areas. Most of the plastics consumed today are considered non-recyclable and are therefore still produced on a petrochemical basis. Our task is to find ways to make plastics that are currently not recyclable or only recyclable at great expense - such as PVC - usable in the circular economy. Will there come a time when we can say that the problem of plastic waste has been solved because the cycle has been closed? Rust: We are a very innovative generation, and developments are constantly ongoing. For example, we have a customer who is working extensively on recycling wind turbine blades. The glass fibre of the blades is still considered non-recyclable, but the customer has made it usable again and can utilise it as a filler for other products. In any case, as in other instances, it all still takes a lot of time. It took 100 years from the development of the first nylon fibre to the invention of nylon tights. In my view, it will probably be a long time before we reach the point where we can say that we have recycling in the plastics industry completely under control. How great is the economic potential? Rust: There are now over eight billion people on the planet, and the world's population continues to grow. This naturally raises the question of what to do with the materials we are all using. If materials are not recyclable, then we will do considerable harm to the world given the enormous number of people. So, at some point, everyone will have to look for solutions and join the circular economy. Here in Europe, we have an economic advantage, because we are pioneers in many areas of recycling, and can export our innovative technologies to other countries. Source VDMA Way2K 2025

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  • "We have never had such efficient systems as we have today"

    Interview on the road to K 2025 with Marcel Perrevort, Chief Sales Officer at Reifenhäuser Marcel Perrevort. Copyright: Reifenhäuser Mr. Perrevort, the next K's motto: "The Power of Plastics" is an expression of the sector's self-confidence. Is this justifiably so in your view?? Marcel Perrevort: Definitely, because we can see that the image of plastic has changed significantly. Today, plastic is no longer seen as a problem, but as a valuable material that can make a significant contribution towards solving many of the world's problems - only if it is used in the proper manner of course. The discussion about plastic has become much more objective and realistic, both among our customers and our employees. Most companies in our industry today want to contribute towards using plastics responsibly. At the same time, operations must be cost-effective. At K, we will be demonstrating that a combination of both is possible. The second part of the motto is: "Green - Smart - Responsible". Where is Reifenhäuser's focus in this respect? Perrevort: We have been active in all three fields for some time now. We are pushing downgauging, meaning the production of ever thinner films with the equal – or even better – properties. This allows us to save a considerable amount of CO2 with a material that often has a better carbon footprint than other packaging materials anyway. The topic of "smart", i.e. digitalisation and automation, is also pushing the CO2 balance: we have never had such efficient systems as we have today, which manufacture high-performance products with minimal raw material consumption, optimised energy use and minimised waste. There have already been quite a few developments, and these are ongoing constantly. However, smart systems are above all a response to the shortage of skilled labour. Assistance systems and automation features help film manufacturers to ensure their productivity and quality – even if perfectly trained staff are not available. And of course, automation also makes systems safer, which brings us to the topic of ‘responsibility’. For us, this includes responsibility towards the environment, towards our own employees and towards our customers' employees. The topics Green - Smart - Responsible are extremely diverse and, in our view, closely linked.. What specific projects are you pursuing in this respect? Perrevort: There are quite a few: in terms of ‘Smart’, we have set up special units for digitalisation and education: RE: GmbH, R-Cycle and our AR:DEL Academy. We have invested heavily in this area and created market-ready solutions that offer our customers added value, not solely for Reifenhäuser machines, but even beyond that. For example, all machines along the value chain can be networked: in addition to an extrusion machine for example, you can connect a printing machine, recycling line and more besides. The aim is to produce more efficiently and sustainably through digitalisation. There is still considerable potential in this area in particular within the plastics industry. To what extent is the struggling economy in large parts of the world slowing down the development of your industry? Perrevort: There are obstacles all across the board. One of these is the overcapacity that has accumulated during the pandemic in particular. This is most prevalent in the hygiene sector, but is also noticeable elsewhere. Investments are still being made in machinery and equipment, but the brakes are definitely on. Many companies are also concerned about geopolitics and the threat of trade barriers, and there are considerable uncertainties. Nevertheless, we are observing the first signs of a slow recovery in the markets. In the meantime, we are continuing to invest in the key future areas, and related added value for our customers. What can be done to manage this widespread reluctance to invest? Perrevort: We support customers in becoming more efficient with their existing equipment. Manufacturers are currently less likely to invest in large new systems with an additional capacity of 1000 kg per hour, but are definitely interested in improving the end quality of the product or making production more efficient. We therefore show what can be achieved with retrofits or special solutions in the field of digitalisation. The solutions yield a quick return on investment and are therefore well received. Customer margins are severely under pressure. Is this pressure at the expense of sustainability? Perrevort: I wouldn't say that. Firstly, awareness of sustainability is already firmly anchored in our industry. Secondly, we can see that there is no turning back on this path. The transition from a linear to a circular economy is being driven forward politically, for example by the new European packaging regulation PPWR, which is now gradually coming into force. This is a particular concern for major brand owners, as many questions remain unanswered in this context, such as where recyclates in sufficient quantity and quality to fulfil the percent recyclate content directive can be sourced – depending on the type of packaging, and how the prescribed recyclate content can be realised for food packaging, where that use of recyclates is often still prohibited by other regulations. All market players are dealing with these questions and working on solutions to be ready for when the enforced turnaround comes. We are convinced that this pressure is necessary. Today, recyclable solutions are often more expensive and would not establish themselves on the market so quickly without regulatory intervention. What developments do you expect to see in the future? Perrevort: I believe we will see a leap in automation at the next K – in film extrusion, but in other areas of plastics processing as well. There will also be another significant leap in efficiency, particularly in those technologies that contribute towards the circular economy. For example, we were able to produce recyclable all-PE mono-material film with a thickness of just 18 micrometres, which means that it can compete economically with conventional PET-PE film for the first time. At the last K, the topic of digitalisation was still relatively abstract. This year we will see many more implementable applications. The trend towards modularity will continue. Customers will decide for themselves how they wish to equip their machines, and to what extent digitalisation will assist them – including AI applications, where the actual benefits can already be seen today, and where enormous potential for improvement is opening up. Source VDMA Way2K 2025

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  • "Plasma technology makes plastics more valuable"

    Interview on the way to K 2025 with Lukas Buske, Managing Director of Plasmatreat Lukas Buske. Copyright: Plasmatreat Mr. Buske, to what extent does plasma technology contribute towards recognising plastic as a recyclable material? Lukas Buske: Plastic is a versatile material and indispensable in many industries. However, many plastics are naturally water-repellent, i.e. hydrophobic, meaning that paints, varnishes or adhesives adhere poorly. Recycled plastics in particular, which often consist of material mixtures, are difficult to process. By pre-treating surfaces with Openair-Plasma, for example, it is also possible to achieve a stable and long-term adhesion of polyurethane coatings on polypropylene, i.e. PP. Recycled plastics also gain in quality through this pre-treatment method, and can partially replace more expensive high-performance plastics, enabling new material combinations. In this way, plasma technology makes plastics more valuable, increasing their recyclability, reducing CO2 emissions, and making an important contribution to the circular economy and resource conservation. How does it help to reduce the CO2 footprint? Buske: Plasma technology offers an environmentally friendly alternative to conventional pre-treatment methods. In contrast to processes such as the application of solvent-based primers, flame treatment, etching or sandblasting, our Openair-Plasma technology does not require any chemical additives, expensive gases or water-intensive processes. In most cases, only compressed air and electricity are required for plasma generation. This not only eliminates environmentally harmful emissions, but also the consumption of resources such as water or solvents. In addition, the treatment is carried out as a dry, precise and automated inline process, reducing handling times as well as storage and transport costs. This saves additional energy and reduces CO2 emissions along the entire production chain. What new markets can you open up? Buske: In general, new markets are opening up for us wherever materials are reliably bonded, printed, coated or sealed. Our R&D department works closely with sales and market managers to identify new applications at an early stage and develop innovative solutions. Promising markets include leisure and wearables. Plasma improves adhesion to modern materials, for example in smartwatches, fitness wristbands or sports and outdoor equipment. There is also great potential in battery technology: plasma treatment can be used to optimise the surfaces of battery cells, which increases the performance and service life of energy storage devices. In the field of electronics and front-end production, plasma can improve the adhesion of display bonding, protective coatings or sensitive micro-components, among other things. Which products and innovations are required? Buske: This is an exciting question, as we have recently launched several innovative processes and products on the market. In the area of process technology, we introduced HydroPlasma at the beginning of the year. This special technology removes both organic and inorganic contaminants – fully automatically and inline. One example is the removal of fingerprints, which is a major challenge in high-tech industries such as display and optics production. In addition, very exciting new activation effects can be recognised. We are also setting new standards in fibre-reinforced plastics, 3D printing and material hybrids. Plasma treatment optimises the adhesion between different materials: for example when joining plastics with metals. This renders more stable and durable hybrid components – a decisive advantage for lightweight construction applications and structural bonding, for example. Why do many users continue to rely on solvent-based coatings despite the advantages of the plasma process? Buske: Many customers may have heard of plasma but are unfamiliar with the technology and its benefits. In other cases, there is a certain amount of scepticism about switching to alternative processes. At the same time however, there is a growing interest in more sustainable options, especially from companies attempting to reduce their CO2 footprint and replace chemical pre-treatments with plasma. To raise awareness of plasma technology, we are focusing on knowledge transfer and cooperation. Our Plasmatreat Academy offers webinars and training courses to provide users with practical information. We also work closely with research institutes, universities and colleges. In this way, we are already incorporating the technology into the training of specialists and promoting its use in future industrial applications. We are convinced that, from a cost-of-ownership perspective, we have clear advantages. How do you see the future of plastics? Buske: Plastics remain indispensable in many industries. Their lightness, stability and versatility make them essential, but sustainability and recycling are becoming increasingly important. I therefore envisage the future of plastics as being developed further in specific areas: more recycling, intelligent material combinations, optimised surface functionalisation or even material substitution will be crucial. One interesting example comes from electromobility: here we are observing a trend towards replacing aluminium trays with fibre-reinforced plastic trays. We will also be able to see concepts for this at the coming K trade fair. Our goal at Plasmatreat is to use innovative technologies to enable more sustainable and efficient plastics processing; thereby preserving plastics as a valuable raw material, while at the same time reducing the industry's ecological footprint. Source VDMA Way2K 2025

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  • "We have to appeal to the people in our region"

    Interview on the road to K 2025 with Anatol Sattel, Chief Sales Officer at Sumitomo (SHI) Demag Anatol Sattel. Copyright: Sumitomo (SHI) Demag Mr. Sattel, to what extent does the motto of K 2025 – The Power of Plastics - Green - Smart - Responsible – strike the right note? Anatol Sattel: It is certainly right to demonstrate self-assurance. The simple fact is that at least 75 per cent of all plastic products will continue to be without alternatives in the future. The motto can also be used to shed a better light on our industry for the urgently needed young talent - after all, the negative image that plastics often have makes recruiting considerably more difficult. However, it is no longer enough for a company to simply declare its commitment to environmental and climate protection, which tends to annoy people because it is perceived as hot air. You won't win any advocates for plastics if you just skim the surface. What needs to be done? Sattel: We are obliged to explain to the public that we are not only open to sustainable products, but that we are also willing to push for technologies that may not immediately lead to increased profits. And, that we are striving for innovations whose benefits will only become clear in a few years' time. This is one key point. The second important point is publicly recruiting new employees, so that we are still able to employ highly qualified people within our field in the future and drive our innovative technologies forward. We are in competition with many industries. If we don't stand up for sustainability in a credible manner, we won't be able to attract young people. Where do you need to start to secure the next generation? Sattel: We have to address people directly, starting in our immediate surroundings. We need to become visible as a company, as an employer, and as part of the region. We also need to show that we are serious about sustainability, both on a small and wider scale. We need to appeal to people before they possibly consider applying for a job with us, and build a good image as a company. That is why we are planning to introduce a family day in the autumn, so employees can then show their children what they do, and what kind of company we are. We will push ahead with those activities, regardless of the current economic headwinds. The shortage of young talent also affects your customers. Will this accelerate the development towards "unmanned" machines? Sattel: That is indeed the path we are taking, which is being paved by digitalisation. Thanks to our networked production, we now have data on how the machines are utilised in a system as a whole. Current customer pressure for efficiency has led us to offer highly automated systems that are easy to operate; this pressure didn’t exist previously. Today, the aim is for a system to run autonomously. What role does efficiency play? Sattel: We were among the first in our industry to switch to all-electric machines. Because energy costs have risen dramatically over the last ten years, the demand for them is correspondingly high. Traditional hydraulic injection moulding machines are very energy-intensive, as an example: oil pumps are always in operation, even when production is not taking place. Thanks to our Japanese parent company, we have been able to add all-electric machines to our product portfolio. So, we were already very well positioned when the sustainability trend hit with force. The goal of sustainability on the one hand, and the high energy costs on the other, are causing production to become much more energy-efficient in all areas. We have the advantage that we have been using this technology for a long time, while others have yet to develop it. Due to the efficiency advantages of all-electric machines, we have also decided that we will no longer build fully hydraulic machines in Europe from 2026. However, we will continue to manufacture them in Asia and offer them in the relevant markets. Can alternative materials also be processed on the all-electric machines? Sattel: The development of new materials, such as biodegradable ones, is the next step on the road to greater sustainability. It is a major challenge, but also a great opportunity, because if we succeed in developing ground-breaking new materials here in Europe, we can open up completely new markets. We would then have the strategic edge over our non-European competitors. The pressure to innovate triggered by the sustainability trend would also bring a major economic advantag. Where do the challenges lie? Sattel: They are manifold; the general conditions are not good. Technology is improving considerably, but new materials and recyclates are usually more expensive than new products based on crude oil. When the price of the fossil-based raw material is very low, people are no longer interested in recyclates. In addition, traditional plastic manufacturers are usually not interested in supporting alternative materials. Another challenge is the generational change that is currently taking place. We need a lot of expertise right now, but the people who have it are gradually retiring. The younger ones are also good, but they have much less experience. Basically, I am convinced that the change in society as a whole definitely harbours great potential for innovation. Source VDMA Way2K 2025

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  • "Our customers are increasingly requesting complete solutions"

    Interview on the way to K 2025 with Michael Lackner, Managing Director at Lindner Michael Lackner. Copyright: Lindner Holding Mr. Lackner, what developments are there in plastics recycling? Michael Lackner: In recent years, we have noticed a trend in the market towards consolidation among our customers. Small recyclers are being taken over and integrated into larger corporate groups. This has had – and is still having – a serious impact on our product range and product and system policy. Larger groups are buying fewer single units and are tending towards systems, increasingly asking for complete solutions, with system boundaries becoming ever broader. This means that sorting processes, washing processes and extrusion processes need to be more closely interlinked. The aim is to be able to cover the process from input to finished recycled pellets with a guaranteed throughput and quality. In view of the high energy costs, process optimisation and improvements in energy efficiency have also become extremely important. What role do cooperations play in this regard? Lackner: At Lindner, we are very good at representing the front end of the recycling process chain. In other words, all the shredding and sorting processes and, of course, washing: that's our specialisation. However, as customers are increasingly seeking complete solutions, we looked for a cooperation partner in extrusion and found the right one in EREMA. Together we can cover everything from the first to last step and provide consistent quality under optimised process conditions. We have founded a joint company for this purpose: BlueOne Solutions, with Lindner and EREMA each owning a 50 percent share in the company. How important are standards in recycling? Lackner: Standards are becoming increasingly important. Of course, there are legal regulations and standards, but there are also a number of initiatives from various customers. Take the field of Cosmetic Packaging Toxicology, also abbreviated to CosPa Tox, for example, which sets standards for high-quality post-consumer recyclates, so that they can be used again in the cosmetics sector. Standards were not that important as long as post-consumer recyclates were only being used in low-grade, simple applications. However, we are now shifting towards much higher-value applications with our technology. Today, we are pursuing the goal of equal or upward recycling and also aim to use recyclates in the food and cosmetics industries. This requires quality standards – standards that are often much stricter than the legal requirements. Many branded goods manufacturers such as Unilever or Procter & Gamble have defined their own quality requirements, also to ensure the safe use of post-consumer recyclates. In short, it is important that standards continue to be driven forward in order to use recyclates in equivalent or higher quality applications, enabling the realisation and guarantee of the required qualities and their guarantee. So, at the end of the day, recyclates will be equipped with data sheets as if they were new materials, enabling customers to place tailored orders? Lackner: That's exactly what it has to come down to, otherwise, we will not be able to achieve the high-quality use of recycled materials; we need this guarantee. Additionally, we need to have the entire process chain under control, otherwise, the question will always arise as to who is responsible if it doesn't work in the end. The guarantee also gives our customers in the recycling industry the certainty that they can also use their complete systems for these demanding business areas. How important is chemical recycling for Lindner? Lackner: There have been many initiatives in the direction of chemical recycling for several years now. It is often completely new players, such as the petrochemical industry, that enter the recycling market via this route. Initially, it was thought that you could simply put everything into the chemical recycling process and end up with a perfect product. It has since become clear that waste also needs to be processed to be chemically recycled. For Lindner, this means that our pre-sorting processes are well suited to preparing the material for chemical recycling. Chemical recycling will usefully complement mechanical recycling. Many material streams that are extracted from waste can be recycled mechanically in a very cost- and energy-efficient manner. However, there are material streams that we are not yet able to recycle mechanically, or not yet so well at present. Chemical recycling processes are the right technology for this purpose – however, I also believe that we are still a long way from reaching the end in terms of quality in mechanical recycling. One of our innovation projects deals with new cleaning processes and the aim of raising the quality to a new level. What innovations is Lindner planning to show at K? Lackner: At K, we will be showing the results of our process optimisation as a consequence of our cooperation with EREMA We will present concrete customer benefits there. In the shredding sector, we will be presenting innovations related to energy efficiency, ease of maintenance and material flexibility. Source VDMA Way2K 2025

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  • "There is a quest for orientation within the market"

    Interview on the road to K 2025 with Bengt Schmidt, Global Director Packaging at Kiefel GmbH Bengt Schmidt. Copyright: Kiefel GmbH Mr. Schmidt, is there a noticeable progression within recycling? Bengt Schmidt: Recycling has been a major issue in the plastics industry for years, with considerable technological possibilities at present, but the processing of recyclates is often still a challenge. At the same time, the demand for recyclates from plastics processors is rising sharply. In many cases however, it cannot be satisfied. The quantities available for recycling from the yellow bag are not sufficient. Processors are therefore often forced to use virgin material. Is this why Kiefel offers machines able to manufacture products from natural fibres? Schmidt: Natural fibres can be a way to replace plastics in packaging. That's why we also offer machines for fibre-moulded packaging, which is ultimately paper packaging. We have now launched the second generation of machines and are already selling them in Europe and North America. However, when you enter a completely new technology, you need partners who are prepared to invest in the necessary resources in terms of personnel and equipment, in order to pave the way for a new solution – in our case, environmentally-friendly packaging. They need to be sure that they will be successful with these products on the market; however, the market is currently still heavily reliant on regulatory support. How do you rate the progress of the circular economy? Schmidt: The overall political situation is causing uncertainty or a quest for orientation in the market, which is influenced by various factors, such as high energy costs in Europe, the renegotiation of trade flows by the new American administration, and legislation such as the PPWR packaging regulation. This in turn means that processors are also holding back on investments, and it also makes it incredibly difficult to establish a circular economy. If you really want something, you have to commit to it, with all the consequences. At the moment, nothing is happening because everyone is waiting. This state of uncertainty is also unsatisfactory for the economy. So, what would need to happen? Schmidt: Individual companies cannot change a great deal, but it would certainly be helpful if the political targets for the circular economy, recycling and recyclates were set lower, and consequently more realistic. When a regulation comes along that makes all plastics processors shake their heads and wonder how they are supposed to implement it, insecurity sets in. However, if you set a target that is considered ambitious but feasible, companies would regain their confidence. At Kiefel, we believe we are very well positioned. We have already developed solutions that answer the questions of the future and still have a lot in the pipeline: some examples include thermoforming with recycled mono-material films or with natural fibres. There is also a lot that we can still do, but we always need a brand owner to drive innovation. What is the situation outside the fibre sector? Schmidt: In the polymer sector, i.e. in the plastics processing sector, Kiefel machines are designed in such a way that they can process a wide variety of plastics, including recyclates, efficiently and with high quality – we will of course also be demonstrating this at this year's K with our latest tilting machine model. Thermoforming machines can handle material fluctuations and impurities better than injection moulding machines, for example, and can handle higher recycling rates. They also have a better energy balance. I am therefore certain that we will be able to generate an increasing share of the market in the future. How does Kiefel ensure its innovative strength? Schmidt: Firstly, through continuous investment in technology, which enables us to optimise our machines. Secondly, through partnerships in research and development, for example, with research institutes such as the Fraunhofer Institute or with universities worldwide. Thirdly, through even closer cooperation with our customers. To this end, we are currently expanding our Customer Innovation Centres worldwide, most recently by adding an integrated laboratory to our headquarters in Freilassing with a focus on polymer. The main aim there is to conduct research into various materials in the field of plastics, together with and for our customers, carry out proof of concepts, produce samples and run various tests, also with regard to moulds. The aim is also to constantly make processes more efficient. Finally, we are involved in numerous industry initiatives, such as Holy Grail 2.0 for example, which focuses on digital watermarks for labelling packaging, and R-Cycle, which deals with a traceability standard for packaging. This involvement serves as an important impetus for our own innovation activities. Source VDMA Way2K 2025

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  • "Ultrasonic technology is safe and user-friendly"

    Interview on the road to K 2025 with Michael Boerner, Head of Global Business Development Plastics and Simon Stadtmueller, Expert Medical Applications at Herrmann Ultraschalltechnik Michael Boerner (l) and Simon Stadtmueller (r) Are there any new product applications for the ultrasonic welding process? Michael Boerner: Ultrasonic joining technology has been used in medical products for many years, for example in infusion sets or in diagnostic tests. Recently, we have seen a strong market trend in the field of wearable medical devices. Especially in the so-called CGMs, i.e. continuous glucose monitoring devices. These are continuous glucose measurement sensors for diabetes patients. What advantages does ultrasonic joining technology offer in this regard? Simon Stadtmueller: It protects the sensor electronics from environmental influences. Patients wear the sensors on their skin for 14 days using an adhesive patch. They can swim, shower and even exercise with the sensors. The plastic casing must therefore be hermetically welded and fixed with an adhesive tape. Components can also be riveted and connected using ultrasonics. This allows for high-strength and flexible connections to be made using ultrasonics. Another advantage is the improved skin tolerance. Adhesives that are often used contain substances such as IBOA or MBPA: skin allergens that many people react to. Ultrasonics eliminates this problem. This technology is therefore safe and user-friendly. It also enhances quality of life, because it eliminates the need for people to prick their fingers to take a drop of blood for monitoring purposes. How big is the market and at what rate is it growing? Boerner: Approximately 540 million adults worldwide live with diabetes. Nearly seven million people die each year as a result of this disease. The number of patients is estimated to reach 780 million by 2045, that means the numbers are skyrocketing. Accordingly, many manufacturers of diabetes technology products are currently growing, and it’s not uncommon to see rates of more than ten percent. However, this growth pattern is not the same everywhere in the world: in many regions, the new products are not available to patients for cost reasons. Through our ultrasonic technology, we want to contribute towards safe and efficient manufacturing technology, in order to make the products accessible to more people. Are there any other applications for ultrasonics in the area of so-called wearables in the pipeline? Boerner: Ultrasonic welding is also used in insulin pumps and other drug delivery devices. The challenges for manufacturers here are very similar. In addition, there are further applications for ultrasonics, especially for components that come into direct contact with insulin or medication. The joining of plastics with membranes or silicone seals is in high demand. This is done in a process-reliable manner, with traceable process data. Here, too, there is a high level of safety for the patient, because adhesives with sensitive active ingredients do not come into contact with the skin. In addition to the diabetes technology market, we also see similar applications for temperature sensors and for ECG sensors, which are needed to measure heart function. These will revolutionise the medical market. Does ultrasonic joining technology also contribute towards sustainability? Stadtmueller: The ultrasonic joining process requires very little energy and no additional joining materials. In contrast, thermal joining processes require heat to be applied to the tool permanently. A large amount of energy is also required to produce adhesives. It is very important for manufacturers and designers to be aware of the options in joining technology, as this is where an important decision for sustainability is made. Boerner: Energy is available everywhere in the world, and no further logistics for consumable materials are required. Ultrasonic technology thereby reduces the CO2footprint of the products. Some of the plastics without additives can be recycled as mono-materials. Of course, recyclates or bioplastics can also be joined using ultrasonics. Herrmann Ultraschall has already conducted many studies with plastics manufacturers in this area. What role do automation and digitalisation play today? Stadtmueller: Our customers use almost exclusively automated manufacturing processes. Reproducibility, quality and process data play an increasingly important role here. In medical technology in particular, processes are validated and of crucial importance for the approval of products according to EU regulations or the US-American FDA. These approvals set a very strict framework for manufacturers. Our customers use our process data for each individual weld for process monitoring, but also for traceability. They enable seamless documentation. The motto of the next K is ‘The Power of Plastics’. What do you think is the power of this material? Boerner: Plastic is a material with many great properties. The power of plastics in medical technology, for example, lies in their ability to enable innovation while meeting the needs of patients and medical professionals. Plastics are not only a cost-effective, but also a life-saving resource. It is up to us to use this material sensibly and in a resource-efficient way. We are on the right track, with recycled materials and bioplastics already finding their way into many areas. Coupled with intelligent joining processes, we should take advantage of the benefits, and further develop these outstanding technologies. Source VDMA Way2K 2025

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  • "Previous major challenges with single-material composites have now been solved"

    Interview on the road to K 2025 with Konstantin Klein, Sales Director of Blown Film at Hosokawa Alpine AG Konstantin Klein Mr. Klein, where does the sustainability concept in blown film extrusion start at Hosokawa Alpine? Konstantin Klein: We have been working extensively on recyclable packaging in blown film extrusion for a long time. We presented the first recyclable PE packaging and the first mono-material composite at K 2013. At that time, the topic was hardly discussed at all. The mono-material composites are produced with our MDO technology, which is based on the monoaxial stretching of blown film. We already made our first attempts in the early 2000s, rendering us pioneers in that field. Recyclable, sustainable packaging is not a new topic for Alpine Hosokawa. Meanwhile, mono-material composites are on the rise. Klein: That's right. At K 2016, we saw the first signs of growing interest. Then a breakthrough came in 2019, with demand increasing enormously, along with a major increase in project requests. For us as a blown film line manufacturer, the topic of sustainable packaging is based on three pillars: one of them is the production of recyclable packaging from mono-materials. The second one is downgauging, i.e. the production of ever thinner film with consistent properties. And the third important pillar is packaging made from recyclates, whether post-industrial or post-consumer recyclates. In the past six or seven years, the momentum in these fields has increased significantly. What challenges does mono-material packaging face? Klein: Plastic packaging has become increasingly complex over the years. Today, packaging combines ergonomics, feel, design, freedom of form and, above all, product safety. Translating this complexity into a single type of packaging is a lengthy technological process. We have already come a long way in this regard – I would even go so far as to say that at present, a single-material packaging can cover the full range of packaging performance. We now have a number of options for creating barrier properties. The difficulties in the production process have also been eliminated. The major challenges in terms of maximum output, minimum waste and good further processability have therefore been overcome. What tasks remain to be done? Klein: Customers are increasingly demanding higher quality end products and greater machine efficiency. In terms of efficiency, the aim is to reduce material losses when changing production, and to reduce edge trimming. This is the key issue in the production of MDO films. It is also about minimising downtime and service intervals. In addition, customers are demanding a higher quality mono-material composite. At the end of the day however, the packaging should be cost-effective, so it's all about increasing productivity. On the one hand, we achieve this through our technologies, such as the Trio System for minimizing edge trimming, or the vacuum roller, which, in addition to reducing edge trimming, also ensures a high level of process reliability. On the other hand, we achieve it through our flexible machines, which enable an immediate response to market changes, and thereby a swift increase in capacity utilisation. Automation plays an important role in that regard. As is the case virtually everywhere else, our customers are struggling with a shortage of skilled workers, which is why they want us to install increasing numbers of assistance systems in our machines. The main goal is the so-called man-less machine, which requires very little skilled personnel to operate. How flexible must machines be today? Klein: The large machines – especially those used to manufacture mono-packaging – have to be extremely flexible. This is because they can currently only be fully utilised with mono-packaging in individual cases. Accordingly, such a machine must be able to produce an extremely wide range of products. A typical requirement from our markets is a seven-layer system with an MDO unit that can be used to produce stretched films for food packaging, i.e. stretched films with or without a barrier. At the same time however, this machine can also be used to produce standard products made of polyethylene or standard barrier films. This gives our customers the opportunity to serve existing markets while also driving innovation in their packaging. Added to this is the uncertainty regarding the future course of regulation. The flexible machine is an excellent solution in this respect, as it provides customers with the security of knowing they will be able to produce efficiently and profitably in ten years' time as well. What role do recyclates play in flexible packaging? Klein: We are witnessing a continuous increase in demand for flexible packaging, particularly from the established European market. Spain and Germany are currently developing very well in this area. Packaging manufacturers are placing ever more importance on increasing the share of recycled materials, be it in simple packaging products such as bin liners, where the share of recycled materials can be up to 100 per cent, or in more sophisticated packaging with a material combination of new and recycled materials, where the proportion of recycled materials is constantly increasing. The challenges in processing recyclates lie in the inhomogeneous quality of the recycled materials. It is therefore challenging to produce a consistently high film quality. Source VDMA Way2K 2025

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