Digitalisation

Artificial intelligence, automation & robotics, and connected value chains – digitalisation is one of the key topics in the plastics and rubber industry. In this section, you will find the most important articles on digitalisation.

Roboterhand und Menschenhand berühren sich, eine leuchtende Glühbirne dazwischen; digitale Linien symbolisieren KI und Innovation.

Results (46)

  • Automated simulation software creates a world map of polymer properties

    Copyright: LightFieldStudios 02/14/2023 "Materials informatics (MI), a new branch of materials research that combines materials data with data science, is gaining traction," said co-corresponding author Yoshihiro Hayashi, assistant professor, Institute of Statistical Mathematics in the Research Organization of Information and Science (ROIS). Hayashi is also affiliated with the University of Tokyo's Department of Mechanical Engineering. "MI applies machine learning to predict new materials with innovative properties and their fabrication methods from a vast design space. As such, data is the most important resource in MI." Despite the need, Hayashi said, efforts to create a comprehensive database of polymer properties to enable data-driven research have fallen short. "To construct a database of polymer properties by molecular simulations, we developed RadonPy," Hayashi said. "It's the first open-source software that successfully automates polymer physical property calculations using simulations of classical molecular dynamics based on atomistic models — which account for the behaviors and characteristics of individual constituents." The program takes an assigned polymer and runs calculations to equilibrate it in prescribed system parameters. Once it does, it can then calculate the polymer’s density, radius of gyration, refractive index, thermal conductivity, specific heat capacities at constant pressure and at constant volume, among other information. RadonPy produces and stores the data, which can then be accessed later. The researchers also implemented a machine learning technique called transfer learning to correct biases and variations between the simulated property values and experimental data. "In this study, more than 1,000 unique amorphous polymers were computed in about two months, mainly using the supercomputer Fugaku," said co-corresponding author Ryo Yoshida, professor, Institute of Statistical Mathematics in ROIS, the National Institute for Materials Science’s Research and Services Division of Materials Data and Integrated System and The Graduate University of Advance Studies’ Department of Statistical Science. "The program implements a set of automatic computation functions for 15 different properties, which were systematically compared with experimental data to validate the calculation conditions. We also comprehensively verified the agreement between six properties obtained from high-throughput molecular dynamics calculations and experimental values." The research team also identified eight amorphous polymers with high conductivity, according to Yoshida. Now, the group is using RadonPy to create the world’s largest open database of polymer physics, with more than 100,000 different polymer species. In addition to ROIS, three universities and 19 companies are partnering to jointly develop other databases with RadonPy for a variety of applications in academia and industry. "This project will create a world map of polymer material properties," Hayashi said. "Such exhaustive observations cannot be achieved solely via experimental approaches requiring considerable costs, such as in material synthesis. This research is the first step toward a new horizon of polymer science." Reference Hayashi, Y., Shiomi, J., Morikawa, J. et al. RadonPy: automated physical property calculation using all-atom classical molecular dynamics simulations for polymer informatics. npj Comput Mater 8, 222 (2022) Source Institute of Statistical Mathematics More around Software & Apps

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  • Machine monitoring: performance data via app at any time

    Interview with Dr. Stefan Heinrichs, Innovations Manager, Steinert GmbH Exclusively for K-MAG Copyright: seventyfourimages 26.10.2022 Steinert.view® is a flexible and reliable monitoring solution for STEINERT sensor-based sorting machines. This monitoring solution makes operating and production data from STEINERT sorting systems digitally available to customers. Dr. Stefan Heinrichs, Innovations Manager at Steinert GmbH, explains in an interview how the technology was developed and what the advantages of the web app are. He sees a great potential for the digital future of STEINERT.view®. Dr. Heinrichs, please explain how the Steinert.view® monitoring solution works and what technical requirements customers need to meet in order to use it. Dr. Stefan Heinrichs: STEINERT.view® makes operating and production data from STEINERT sorting systems available to our customers in the simplest possible way. The performance data collected by the sorters, such as belt occupancy or particle size distribution, is visualized in a web app. This enables the operator to see at a glance whether his or her machines are currently producing or whether there are problems. Changes in production can be tracked, as can optimization potential, for example in the utilization of machine capacity. In order to be able to send data securely to the cloud environment, a sorting system is required that is "IoT ready". The IoT-Ready package can be retrofitted for machines built in 2018 or later. To view STEINERT.view®, the customer needs a smartphone or tablet with an internet connection, on which the app from the popular app stores can be installed. Alternatively, the application also runs completely in the browser. What are the benefits for users of Steinert.view®? Heinrichs: Depending on the size of the company and the plant, the additional display of detailed operating data of the sorting systems in a control station often falls victim to the red pencil during the project planning of a sorting plant. Later programming by the control system supplier is costly and interferes with the operating sequence, which is why this is often not implemented subsequently. STEINERT.view® offers the possibility of retrofitting this functionality, as the visualizations are already implemented here and the data is provided directly by the sorting systems. Sorting systems that are not integrated inline into large processing lines usually also do not have large control stations or a central control system that processes this data centrally. Here, STEINERT.view® provides a useful supplement, since even widely placed plant sections can be kept together in view in the app. A noticeable reduction in downtimes due to improved machine monitoring is an advantage to be named. In the plant constellations described, however, it can be an advantage for the operating sequence alone if the operator can save trips to the machine or already knows which tool he or she should take with him or her in the event of an indicated error message. What prompted the development of the technology? Heinrichs: The circular economy is constantly striving to make processes and technology more efficient. In addition, there is an increasing effort to make better use of potentials from the data that accumulates. STEINERT.view® now enables our customers to obtain more orientation for better control of their processes in a simple way. There has long been a desire to make this data available in mobile form. We have succeeded in doing so with the web app, which responsively serves different display formats. This means that the performance data of the machines can be accessed on smartphones, tablets or directly on the PC from any location and at any time. How do you plan to continue driving change in the future? Heinrichs: Currently, the focus of STEINERT.view® is on making operational data as conveniently accessible as possible according to the mobile-first approach. But that also means only presenting data from which customers can derive a direct benefit. STEINERT listens very carefully when customers report on their needs in daily plant operation, which is why the wishes of our customers will continue to be a central component of further customer-driven developments in the future. All developments are aimed at enabling customers to make the best possible use of their investments and to recover raw materials as efficiently as possible. At the same time, our own experience in using our systems enables us to see potential and evaluate it in close consultation with our customers. This circumstance offers an important point of contact between us and them, in which we can further strengthen our competence beyond the supply of machines as a supplier of solutions and as a constructive partner. For the future, this also means making greater use of the potential offered by digital networking. This can mean integrating further data sources and combining them with additional data evaluation in order to obtain an ever sharper picture of the reprocessing processes and to derive necessary actions directly for operations. The focus here is on strengthening process automation, although long-term topics such as the networked value chain, for example through a digital product passport, also hold further potential on the way to an integrated circular economy. Kyra Molinari (K-MAG Editorial Team) More around Software & Apps

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  • Humanoid Robots in Plastics Processing – Innovation with Potential

    The future of the plastics industry is humanoid Exclusively for K-Mag The use of robots, including in humanoid form, will become increasingly commonplace. Copyright: sittinan- stock.adobe.com 25.06.2025 According to a recent market study by Nexery, around 20 million humanoid robots could be in use worldwide by 2030. These human-like machines open up new opportunities, especially for plastics processing companies: They are flexible in use, do not require fixed programming and can also be integrated into existing plants ('brownfield'). Repetitive and physically demanding tasks such as loading machines , internal transport or quality control are particularly suitable areas of application. At the same time, they can alleviate the shortage of skilled workers – a challenge that particularly affects medium-sized plastics processors. Humanoid robots in industry: Use cases The development of humanoid robots is progressing rapidly. The first models are already in use in pilot applications – including in the plastics industry. A look at four current solutions: Apollo from Apptronik is being tested in production at Mercedes-Benz, among other places. Copyright: Apptronik 'Apollo' from Apptronik The humanoid robot Apollo from the US manufacturer Apptronik was developed specifically for industrial use and is being tested in production at Mercedes-Benz , among others. Apollo has a modular design, can lift loads , operate machines and move autonomously within a space . Thanks to AI support, it adapts flexibly to different working environments. Figure 01 from Figure AI was tested at BMW's US plant in Spartanburg in 2024. Copyright: Figure AI 'Figure 01' from Figure AI With its Figure 01 model, Figure AI has developed a humanoid robot that has already been tested at BMW 's Spartanburg plant in the US for use in car body construction. It can operate with both hands , perform complex gripping movements and is currently being used by its first commercial customers in real production environments. This makes Figure one of the pioneers in the industrial use of humanoid robots. Iggy Rob from igus is a partially humanoid low-cost robot for industrial applications. Copyright: igus 'Iggy Rob' from igus With Iggy Rob , Cologne-based motion plastics specialist igus is launching a cost-effective, partially humanoid robot for industrial use. The robot does not have legs and moves on a stable, wheel-driven platform. Among other things, it can be used to insert components into injection moulding machines . 'The world is made for humans, so the potential for humanoid robots is huge,' explains Alexander Mühlens, Head of Low-Cost Automation at igus. Iggy Rob is available at a starting price of €47,999 , making it significantly cheaper than many comparable humanoid systems. Digit from Agility Robotics is being tested at Schaeffler in plastics processing, among other areas. Copyright: Schaeffler 'Digit' from Agility Robotics The humanoid robot Digit from Agility Robotics is being tested in pilot projects at automotive supplier Schaeffler . In plastics processing, for example, it can be used to load and unload injection moulding machines . The long-term goal is to integrate humanoid robots into the global factory network. The focus here is on flexibility: through the use of artificial intelligence, humanoid robots can respond to changing tasks and move autonomously in the production environment. Study: Industry Expects Humanoid Robots to Be in Use in 3–10 Years According to a study by Fraunhofer IPA with over 100 respondents, many companies see humanoid robots as a realistic option in industry – especially in the areas of material transport , order picking and machine operation . 74% of respondents expect them to be in use within the next three to ten years. Did you know? Just a few years ago, humanoid robots were primarily the stuff of films. Today, they can be found in the machinery of medium-sized companies. Many parts of humanoid robots are themselves made of high-performance plastic components. The 4NE-1 humanoid robot from NEURA Robotics weighs around 60 kg and is 170 cm tall. Challenges: Costs, Safety, Acceptance Despite all the progress made, challenges remain for the use of humanoid robots: Investment costs of up to €100,000 are currently still a barrier to entry – even though prices are falling. Functional safety and acceptance by the workforce are also key issues. Especially for SMEs, ease of use and integration without complex programming is crucial. Outlook: A Topic for Tomorrow's Strategies The technology is still in its infancy – but it is developing rapidly. Initial pilot projects show significant increases in efficiency and quality. Those who test early can secure advantages in the medium term. According to Nexery, the ROI is around 100% in the medium term . For innovation-driven companies, now is the time to gain initial experience in order to be one step ahead tomorrow. The portrait was generated by AI. Author: Elena Blume | K-Mag Elena Blume has been writing for various industry magazines for eight years and joined the K-Mag editorial team in 2021. She is particularly interested in topics related to innovative plastics solutions that contribute to sustainability and address current challenges relevant to industry and society. At a glance Humanoid robots are conquering the plastics processing industry: they take on flexible, stressful tasks and could become the production standard in just a few years. Large companies and SMEs are already testing the first applications. More around Digitalisation

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  • Smart Extrusion for Sustainable Film Production

    Reifenhäuser at K 2025 Exclusively for K-Mag 07.10.2025 With innovative extrusion systems, digital services, and smart training solutions, the Reifenhäuser Group is tackling current challenges such as skills shortages and sustainability requirements. At K 2025, the company will be presenting technologies relating to automated extrusion, AI-based process optimization, and recyclable monomaterial packaging. K-Mag spoke with CSO Marcel Perrevort. What does your company stand for—and what makes your product or service portfolio particularly special? Marcel Perrevort: The Reifenhäuser Group is the world's leading specialist for extrusion lines and components. Our aim is to give customers a competitive edge through innovative technologies, digital solutions, and excellent services. With our Blown Film, Cast Sheet Coating, and Reicofil business units, we cover a wide range of film and nonwoven applications, complemented by high-end components from Reifenhäuser Extrusion Systems, Reiloy, and Kdesign. Our portfolio ranges from complete systems to intelligent software solutions and training—always with the goal of measurably increasing performance, quality, efficiency, and sustainability. Automated extrusion and smart data in focus at K 2025 What topic or innovation will you be bringing to K 2025—and why is it relevant to the industry? Perrevort: Under the motto “Boost Your Performance,” we will be showing how film manufacturers can produce profitably and future-proof their operations despite the shortage of skilled workers. The focus will be on three areas of innovation: automated extrusion, smart data, and innovative training. One highlight is the second generation of our unique PAM system, which automates the adjustment of coextrusion adapters, dies, and other downstream components—a decisive step toward greater process reliability and independence from skilled personnel. With new MDO technologies and downgauging solutions, we also demonstrate how recyclable mono-material packaging can be produced at competitive costs. In this way, we are contributing to the implementation of the European PPWR and supporting our customers in developing sustainable business models. The plastics and rubber industry of the future will be digitally networked, highly automated, and sustainable—combining technological excellence with economic and ecological responsibility. Marcel Perrevort, Chief Sales Officer Reifenhäuser Group Discussing together: Solutions for skilled labor shortages and sustainable packaging What would you like to discuss with visitors at K 2025 – what is particularly important to you? Perrevort: We want to discuss concrete added value for our customers: How can operational excellence be achieved through automation, digitalization, and training? How can sustainable packaging be convincing not only technically but also economically? And how can the potential of data – with our new solutions under the Reifenhäuser NEXT brand – be used to make processes more efficient? The use of AI will play a decisive role here. Copyright of images belongs to: Reifenhäuser Group What are your expectations for participating in K 2025 – and what are you personally most looking forward to? Perrevort: K is the most important stage for our industry. We expect intensive discussions with customers, partners, and new prospects in order to present solutions for current challenges such as skilled labor shortages, cost pressures, and sustainability pressures. Personally, I am looking forward to showcasing the enormous range of our innovations live for the first time—from high-tech systems and automation to digital services—and experiencing firsthand how these innovations are received by our customers. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) The portrait was generated by AI. Editor: Simone Ernst | K-Mag Simone Ernst has been writing for various industry magazines for eighteen years and has been part of the K-Mag editorial team since 2024. She is particularly interested in topics such as plastics recycling, sustainability in the plastics industry and career paths in the plastics and rubber industry. At a glance Reifenhäuser will be presenting innovative solutions for film production at K 2025 under the motto “Boost Your Performance.” The focus will be on practical discussions about digital services, AI applications, and future-proof business models. More around Digitalisation

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  • plastics.ai: Expert Knowledge on Demand – Hanser Verlag Launches AI Chatbot for Plastics Technology

    Quick access to reliable specialist literature for industry, development and training plastics.ai is Hanser Verlag's new AI chatbot for plastics technology. It displays answers and literature simultaneously in a split screen. Copyright: Hanser 15.09.2025 With the new AI chatbot plastics.ai, Hanser Verlag offers a digital solution for experts in the plastics industry: whether it's material selection, process optimisation or recycling – plastics.ai provides well-founded answers in a matter of seconds, based on quality-checked specialist literature. With plastics.ai, plastics engineering professionals receive answers based on quality-checked technical literature. Copyright: Hanser Digital Support for Plastics Processing From tool design and process monitoring to sustainability strategies, plastics.ai provides support along the entire plastics value chain. The application answers technical questions from practice and development based on verified sources – transparently documented in a split screen with the original source. Compared to general AI chatbots, whose information is often based on unverifiable web sources, plastics.ai draws on an exte nsive knowledge database of over 60 specialist publications from Hanser Verlag – including standard works on plastics technology, titles on the circular economy and the latest research results. The AI chatbot plastics.ai supports industry, development and education with practical information. Copyright: Hanser Target Groups in Industry, Teaching and Development plastics.ai is aimed at a broad specialist audience: Plastics processing companies (e.g. injection moulding, extrusion, thermoforming) Mechanical engineering, design and production planning Quality management and technical services Universities, vocational schools and continuing education providers Raw material manufacturers and recycling companies plastics.ai is also a useful tool for related areas such as sales, customer service and marketing , helping users to better understand technical contexts and make informed decisions. Thanks to integrated source references, plastics.ai ensures transparency and traceability for all answers. Copyright: Hanser Technological Basis and Security The AI chatbot is based on a modern RAG (Retrieval Augmented Generation) system that combines language models with targeted information retrieval in a curated database. Key features: Multilingual: Understanding and responding in over 80 languages GDPR compliant: EU hosting for maximum data security Access: Via any web browser, no installation required Licence models: Available for single and multiple users For more information and a free trial, visit: www.plastics.ai . Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Source Carl Hanser Verlag At a glance Hanser Verlag has introduced plastics.ai, the first AI chatbot for plastics technology. The application answers practical questions about material selection, process optimisation, recycling and digitalisation – based on verified specialist literature. More around Digitalisation

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  • "Industrial communication will change”

    Industry interview with Dana Ford, Auxiliary Controls Engineer for Material Handling/Auxiliary at Wittmann Inc OPC UA stands for “Open Platform Communications Unified Architecture” and was developed to facilitate communication and data exchange between machines. Copyright: Wittmann Inc. Mr. Ford, the OPC UA standard is still largely unknown in the USA. Why is that? Dana Ford : Although OPC was originally developed in North America, it was initially not very well known in the plastics industry. This has only changed recently. The European market in particular has experienced considerable growth in recent years with the introduction of the OPC UA protocol. In the plastics industry in the USA, this new protocol is actually hardly widespread. Users here are still very reluctant to change their established communication channels. Once implemented, these paths are difficult to adapt, mainly due to the associated costs of upgrading equipment and software. As a result, many customers still rely on established FieldBus systems for direct communication with field devices within a work cell. With the introduction of the Wittmann WorkCell, it is now possible to easily integrate all Wittmann peripherals into the injection molding machine using OPC UA. Dana Ford, Auxiliary Controls Engineer for Material Handling/Auxiliary Wittmann Inc Are there competing communication standards? Ford : Indeed, MODBus, Profinet and DeviceNET-ControlNET are widely used communication protocols. These protocols are generally referred to as FieldBUS. However, it is important to understand their limitations. Despite their efficiency in handling real-time communication, these protocols are inadequate when it comes to ensuring secure communication. They also have limitations in terms of the amount of data that can be collected. However, the integration of larger, more cost-efficient processors has initiated a fundamental change. The prevailing trend now is the introduction of protocols that not only enable faster communication, but also ensure the secure and efficient collection of large amounts of data. OPC UA is a perfect solution for this. Many European companies in the plastics machinery industry are taking the lead in developing uniform standards for machine communication. Wittmann is one of them. Why are you doing this? Ford : Wittmann has always been a leader in the development of devices that have advanced monitoring and analysis capabilities. This commitment allows Wittmann to invest time in standardizing and refining the software. We want tomshare our findings with the groups that set uniform standards for effective machine communication. With the introduction of the Wittmann WorkCell, it is now possible to easily integrate all Wittmann peripherals into the injection molding machine using OPC UA. The aim is to provide customers with not just a device, but an entire process that significantly increases their production capabilities. The industry is entering a phase in which suppliers are increasingly being forced to comply with higher standards. The demand for field devices that provide ever more comprehensive data sets is driving the continuous analysis and refinement of the production cycle. At the same time, the seamless integration of peripheral devices with simplified connections and shortened commissioning times should reduce the burden on the production cycle. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Wittmann Group offers its customers injection molding machines and the associated peripherals. If a customer orders a complete solution from you, do they even need an open standard such as OPC UA? Ford : Yes, because even though Wittmann manufactures all these devices, the true potential of these tools can only be fully exploited if they communicate beyond the boundaries of a production cell. Devices such as injection molding machines are needed to connect with MES systems for job planning or to collect historical data for quality control. Imagine that a customer wants to use their injection molding machine with MES connectivity for production data, but also needs accurate data on material consumption, which can be obtained via a gravimetric resin mixer or resin feeder to record resin consumption. In response to these requirements, the provision of an OPC UA package for all systems in the plastics industry is increasingly becoming a prerequisite. Why is it also important for manufacturers of peripheral equipment to have access to a standardized communication standard? Ford : In the industrial sector, secure data exchange between machines is extremely important, whether for production planning, operation or quality control. In a broader sense, this results from the requirements of industry, which is constantly improving technological progress. Think back to the days when you had to fight your way through a maze of cables and drivers to connect a printer to a PC. Today, the USB cable has become the norm and all you have to do is plug it in. Industrial communication will change in a similar way. In the past, you had to struggle with serial cables, baud rates and terminating resistors to configure a water temperature controller to interface with an injection molding machine. Now, however, we are seeing a shift towards improved connectivity. For example, the introduction of standard communication protocols allows us to connect a water temperature controller to an injection molding machine by simply plugging in a standard Ethernet cable that allows for quick detection and control. Where do you need to start in the USA so that customers find the plug-and-play solution of OPC UA so attractive that they implement it? Ford : The first step is to identify the specific requirements of the plastics processor. For example, in industries such as medical technology or FDA regulations, where comprehensive data tracking is required for quality control, it is beneficial to connect to the customer's established MES or SCADA system. In particular, these customers are always looking for connectivity to the injection molding machine, increasingly tending to adopt Ethernet protocols such as Euromap for injection molding machine integration, leveraging OPC UA standards. In addition, the strategic advantage of linking Wittmann peripherals via an OPC UA connection enriches the overall connectivity framework. On the other hand, if a customer only wants to increase production efficiency by reducing start-up times and mold changes, the use of an injection molding machine work cell is a more attractive option. In this scenario, all peripheral devices are connected via OPC UA, allowing seamless integration and setting of peripheral devices from a central location on the injection molding machine. This lean approach significantly shortens commissioning times. This makes it particularly interesting for plastics processors who have to carry out frequent mold changes. Source VDMA More around Digitalisation

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  • Revolutionising waste management: AI improves sorting efficiency and material purity

    Interview with Parshva Mehta, Co-founder & COO, PolyPerception Exclusively for K-Mag Artificial intelligence (AI) improves sorting efficiency, recovery rates and material purity - revolutionising waste management. Copyright: hiv360 – sdobe.stock.com 03.04.2024 Waste management is undergoing a transformation like never before, thanks to cutting-edge technologies such as artificial intelligence (AI) and machine learning. Companies like PolyPerception are at the forefront of this revolution, redefining how waste is sorted and managed to meet the growing challenges of the industry. Parshva Mehta. Copyright: PolyPerception In the interview with K-Mag, Parshva Mehta explains how he and his co-founders want to revolutionize waste sorting with advanced AI models. Can you describe PolyPerception's mission and how it's addressing the challenges in waste management and recycling industries? Parshva Mehta: The motivation behind starting PolyPerception stemmed from a recognition of the growing challenges in the waste management industry, particularly around achieving high material purity and sorting efficiency with increasingly ambitious recycling targets. We saw an opportunity to leverage cutting-edge technologies like AI and deep learning to address these issues head-on. At its core, PolyPerception utilizes advanced AI models tailored for sorting lightweight packaging materials, which are a significant part of waste streams in Europe. By applying deep learning, we're able to analyze waste streams, optimize sorting processes, and provide plant operators with actionable data for better decision-making. The most important parameters can be set and tracked in the fully customisable dashboard. Source: PolyPerception Could you delve a little deeper into the technology behind PolyPerception and how it enhances waste sorting? Mehta: We utilize deep learning and vision-based sensors to analyze the waste sorting process at critical points, providing valuable data to operators. Initially, our focus is on accurate measurements of throughput, recovery rates, and output purity. This data lays the foundation for optimizing and eventually automating the sorting process. Our collaboration with TOMRA is crucial here, as it allows us to integrate our analyzers with their sorting machines for a more efficient process. Our AI models are designed to adapt to different waste streams across Europe, ensuring reliable classification of various materials, such as polyethylene, polypropylene, PET, and more. We tackle challenges like model adaptability, maintaining accuracy over time, and automating the model training process. These efforts aim to provide consistent and accurate sorting across various regions. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Adaptability seems to be a crucial aspect of your technology. How do you ensure your models remain effective across different regions and waste compositions? Mehta: Our deep learning models are designed to adapt and generalize across varying waste streams. This means they can accurately classify waste, even as the types of materials in waste streams evolve. It's all about ensuring consistency and reliability in a continouosly changing sorting process. This adaptability ensures consistent and accurate data measurements, even as new materials enter the market or existing ones undergo changes, thereby maintaining the efficiency and reliability of the sorting process. It can be sorted to the individual target quality by continuously monitoring key contaminants such as white, opaque and solid bottles. In this way, contamination in the washing line can be minimised. Source: PolyPerception How does this work exactly? Do you have an example? Mehta: Our system targets two primary customer segments: sorting plants and recyclers. A standout example is our collaboration with Indaver in Belgium, leveraging the PMD system for lightweight packaging waste. Indaver utilizes our technology across five sorted streams to meet purity levels set by the producer responsibility organization, Fost Plus. Traditional audits were sporadic and unrepresentative of continuous operations. By integrating our systems, Indaver achieves around-the-clock monitoring of output stream purity, enhancing efficiency and compliance significantly. Your collaboration with TOMRA has been highlighted as a significant milestone. Can you elaborate on the importance of this partnership? Mehta: Our collaboration with TOMRA began at the end of 2022, aiming to integrate analyzers into their customers' sorting processes for enhanced data insights. This partnership evolved when TOMRA acquired a 25% stake in PolyPerception, deepening our relationship to improve and monitor sorting lines comprehensively. This strategic move addresses the industry challenge of disparate machinery communication, aiming for a unified, automated sorting process. Such integration and strategic partnerships are crucial for advancing automation and efficiency in recycling operations, reflecting our long-term vision of close collaboration with TOMRA. Suppliers' materials can be accurately assessed, thus avoiding inappropriate costs for the material fed in. Source: PolyPerception Looking to the future, what are your visions for the waste management industry, and how does Polyperception plan to contribute to that vision? Mehta: I'm imagining a world where waste sorting isn't just a static, one-size-fits-all process but one that adapts in real-time to the kind of waste it encounters. Right now, the sorting systems are pretty rigid, but imagine if we could analyze the waste flowing in, learn from the sorting results, and then adjust the machinery on the fly to improve efficiency. This means adding more sophisticated analyzers and leveraging deep learning to not just process waste better but also to handle a diverse range of waste qualities from different regions. It's about making the whole sorting process smarter, more adaptive, and ultimately, more efficient. And finally: What are the next steps for Polyperception in terms of product development and market expansion? Mehta: In the short term, we'll continue focusing on European waste sorting and recycling markets. Looking forward, we're exploring expansion outside Europe, particularly in the US. Product-wise, we aim to deepen our integration with TOMRA's sorting machines, leveraging our data for smarter sorting processes. Stephan Weiner More around Artificial Intelligence

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  • PLASTICS and the VDMA must work together on OPC UA

    Industry interview on OPC UA with Glenn Anderson, Chief Operating Officer at the Plastics Industry Association (PLASTICS) and Thorsten Kühmann, Managing Director of the VDMA Plastics and Rubber Machinery Association OPC UA enables machine-to-machine communication and data exchange. Copyright: Funtap – stock.adobe.com This year, the NPE2024 is taking place again for the first time after a six-year covid break. What are your expectations for this event? What is the significance of the trade show for the American/international plastics industry? Glenn Anderson: It has been six years since we held NPE 2018, because we had to cancel NPE2021 due to Covid, so we have some catching up to do. In this long time, companies in the plastics industry have continued to innovate. It is quite possible that many of them will present not just one innovation, but several. I know from talking to our members and other exhibitors that they can hardly wait to present their technologies at the NPE2024. We are expecting more than 2,100 exhibitors, 700 of whom will be exhibiting at the NPE for the first time. In addition, we are dealing with a changed attendees structure. In view of the changing workforce dynamics, many of the attendees from NPE2018 will no longer attend - mostly for reasons of age. We estimate that over 50 percent of participants will be attending the NPE for the first time. And therefore we must provide content that attracts a newer and younger audience. We are making it easier for processors to obtain meaningful data. Glenn Anderson, Chief Operating Officer Plastics Industry Association (PLASTICS) What have you changed? Anderson: The most important task for PLASTICS and for NPE2024 is, of course, to ensure that we have qualified buyers. So that exhibitors can not only present their technologies, but ultimately also sell their goods and services. In addition we are increasingly addressing a younger audience and have therefore added new content to our concept. For example, for the first time there will be over 100 educational events on a wide range of topics. Our aim is to bring the next generation of workers in the plastics industry up to speed so that they are able to pursue a career in the industry. PLASTICS and VDMA Plastics and Rubber Machinery have a common mission at this show: to highlight the benefits of OPC UA for plastics processors. What exactly is OPC UA and why is it so important to promote it? Thorsten Kühmann: OPC UA is a technology that enables machine-to-machine communication and data exchange. It is a language that is actually spoken between machines. The OPC Foundation provides the grammar of this language, while we, the community of machine builders, define the words. Both grammar and words must come together for this communication between machines to work. This machine-to-machine communication is completely independent of the manufacturer. It doesn't matter who they are or where they come from. The communication works in the USA, in India, in Europe, in China, simply everywhere. That is our mission. Everyone has to agree on a system. As machine manufacturers, we do this for our customers. They should no longer have to worry about whether they can connect machines to each other or how they have to do it. It simply has to work for them. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Why is it important for PLASTICS and the VDMA Plastics and Rubber Machinery to work together on technical guidelines? Anderson: I think the most important reason is that PLASTICS and VDMA share many of the same members. And they all serve the global market. Many US-based customers have plants all over the world. They would definitely be affected by what we're trying to do: make it easier for a processor to get meaningful data. It is important that we work together to ensure that the international technical guidelines we develop are accepted and applied worldwide. OPC UA is a technology that enables machine-to-machine communication and data exchange. Thorsten Kühmann, Managing Director VDMA Plastics and Rubber OPC UA should become the global language of production. Does the NPE have an influence beyond the American market? Anderson: It certainly has. Over time, NPE has developed into a major international platform. The relocation of the trade fair to Orlando in Florida also contributes to the fact that many Latin Americans visit the trade fair. We are expecting visitors from 110 countries. And we are estimating that around 30 percent of all visitors will come from outside the United States. Kühmann: The increased importance of the NPE is extremely helpful for us. It is exactly the right place to present and publicize OPC UA to a large community. We have representatives from all over the world there. If you have such an international audience in one place, you can address international topics all the better. You can summarize it like this: The international production language meets the international community at a major trade fair like the NPE. Your mission is to highlight the benefits of OPC UA for the users, the plastics processing companies. Can you give some practical examples? Kühmann: A manufacturing company that owns several injection molding machines from different manufacturers can operate them uniformly via one control system with an OPC UA interface. This makes the production process more efficient, and the connection of new machines requires significantly less implementation effort. As an industry, we are facing fundamental changes worldwide that we have to deal with. Energy consumption must be reduced, as must CO2 emissions. We have to use materials efficiently and sparingly and we need cost-effective production. All of this requires very precise system control. The first step towards this is always well-coordinated communication in the system and the handling of control data. OPC UA provides the basis for all of this. OPC UA also helps in dealing with the important question that Glenn raised at the beginning: the shortage of skilled workers. There is a worldwide shortage of qualified young people. But if you are supplying high-precision machines and cutting-edge technology and there is a shortage of people who can control these systems, then you need digitalization to simplify the system and make it work. OPC UA makes this possible. Source VDMA More around Automation & Robotics

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  • Material determination at the touch of a button using NIR spectroscopy

    Exclusively for K-Mag The mobile NIR spectroscopy solution from trinamiX helps to identify plastics during plastics recycling. 25.09.2024 Plastics industry strives to recycle plastics as comprehensively as possible. However, this is not always so easy – especially when different types of plastic are difficult to distinguish visually. This is when near-infrared spectrometers (NIR) come to the rescue, identifying the types of plastic and thus facilitating further processing. The company trinamiX manufactures a mobile NIR spectrometer that is particularly suitable for identifying multi-material and mono-material films. However, the application is also able to recognize 30 types of plastics, including standard plastics (HDPE, LDPE, PP, PET, PS, PVC) and technical plastics (PA, ABS, PC, PLA). It is also able to quantify mixtures of PE and PP. In this interview, Dr. Nils Mohmeyer, Director Mobile Spectroscopy at trinamiX, explains the advantages for users and the industries for which the NIR spectrometer is suitable. Dr. Nils Mohmeyer, Director Mobile Spectroscopy at trinamiX Dr. Mohmeyer, for which industries and end users is your product suitable? Dr. Nils Mohmeyer: The mobile NIR spectroscopy solution from trinamiX can be used along the entire value chain: starting with the design of industrially sortable packaging, through quality control of incoming and outgoing plastics, to sorting for better recyclability. Mobile identification of plastics and textiles is of interest to the manufacturing industry (in particular plastic and plastic packaging manufacturers), the textile and clothing industry as well as recyclers of plastics and textiles. As the solution can be used without prior knowledge of spectroscopy and has an intuitive user interface, it can be used at the sorting plant in the recycling center as well as in the laboratory, incoming goods inspection and in the packaging design studio. In order to meet the specific requirements of textile recyclers, we have developed a semi-automatic system that is built into a sorting table and triggers the scans using an integrated sensor. How does the NIR spectrometer distinguish between different types of plastic? Mohmeyer : An NIR spectrometer can distinguish between different types of plastic based on their spectral properties. Each plastic has a unique spectral signature, which is generated by the absorption and reflection properties in the near-infrared light range. The spectrometer captures these patterns and enables the identification of plastic types. What impact does the precise identification of plastic types have on the efficiency and quality of the recycling process? Mohmeyer : Thanks to the clear identification of different types of plastic, materials can be separated by type. This is an important prerequisite for efficient recycling and high-quality recyclates and therefore the basis for a circular economy. In addition to sorting, identification is also important for quality control. Reliable material identification with the mobile NIR spectrometer from trinamiX significantly simplifies the inspection of incoming materials and the release of sorted plastic and textile bales. It also supports non-conformance management and the efficient management of complaints, reducing the risk of costly errors and delays. Our solutions enable companies not only to perform spot checks, but also to comprehensively document incoming and outgoing material flows, visualize and analyse them, thus creating comprehensive transparency for manufacturers and recyclers of plastics. NIR spectroscopy can be used to quickly identify plastics that cannot be distinguished optically. What are the benefits of cloud-based data analysis and the connected customer portal for recyclers and manufacturers? Mohmeyer : The data measured with the spectrometer is analyzed using chemometric models in the cloud provided by trinamiX. This ensures that up-to-date and powerful algorithms are available at all times. All measurements are stored in the cloud and can be accessed simultaneously both in the app and in the customer portal. Users can access current and historical data at any time via the customer portal, even for different devices and measurement campaigns. This opens up a wide range of possibilities for comparing measurements, analyzing and optimizing processes and documenting quality controls. Real-time monitoring is also possible. The identification of plastics also works without an internet connection. The data is then stored on the device and sent to the cloud at the next opportunity. An advantage in regions with unreliable mobile networks. How long did the development take and what challenges did you have to overcome? Mohmeyer : trinamiX started developing infrared sensors in 2016 and launched the first complete spectroscopy solution in 2020. Since then, we have been continuously improving our products and applications and adding new features. A particular challenge was the miniaturization of the hardware and the parallel development of digital solutions and applications. However, thanks to the good cooperation of all developers, we have mastered these tasks well. What feedback have you received from customers about using the mobile NIR spectrometer? Mohmeyer : Very positive! Customers have confirmed that they can identify plastics within seconds and with ease. They are particularly positive about the compact size of the device and the fact that they can use it to go directly to the delivered bales to distinguish the types of plastic on site. When it comes to areas of application, our customers repeatedly mention quality control. Here, the trinamiX solution is used very frequently, for example when checking plastic mixtures. They compare a product sample with the reference sample. The fast result thanks to the trinamiX spectrometer often saves up to a day's testing time in the laboratory. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Kyra Molinari More around Digitalisation

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  • Digital Recycling Tool

    How CYCLOPS is Transforming the Circular Economy Exclusively for K-Mag CYCLOPS is a free open source platform for the plastics recycling industry. It supports waste owners, recyclers and processors in making the best economic and environmentally friendly recycling decisions. Copyright: SKZ 03.07.2024 An innovative tool called CYCLOPS – Circularity Optimisation for Plastics has set itself the task of closing the gap between the need for information and the supply of recycled materials. By providing comprehensive data and assessments, it helps companies to make more sustainable decisions and organise their production processes in a more environmentally friendly way. Dr Jan Werner, Group Leader 'Sustainable and Circular Products', SKZ – Das Kunststoff-Zentrum. Copyright: SKZ In an interview with K-Mag, Dr Jan Werner, Group Leader 'Sustainable and Circular Products' at the SKZ and one of the developers of CYCLOPS, explains how the tool came about and how it works. How did the idea for this innovative tool come about? Dr Jan Werner: The idea for CYCLOPS was rooted in the fundamental question of how we could improve the recycling process and use more recycled materials in production. We realised that there is a significant information gap between the players in the Circular Economy – an obstacle that prevents efficient material use. Through our previous collaborations between the SKZ, the Wuppertal Institute, CIRPLUS and Green Delta, we saw an opportunity to address this deficit with a centralised information offering. Could you describe the core functionality of CYCLOPS in more detail? How does the tool specifically support the selection and use of secondary materials? Werner: CYCLOPS serves as an information hub that provides detailed data on recycled materials and thus enables informed material selection. For example, the tool offers special views and assessments for different user roles, such as recyclers or material users. A central aspect is the ecological assessment of recyclates, which shows users the advantages of recycling over the use of virgin materials, including savings in CO₂ emissions and other ecological benefits. Tools like CYCLOPS close information gaps and promote the Circular Economy by supporting more sustainable decisions. What are the specific challenges in the recycling process that CYCLOPS addresses? Werner: In addition to improving the flow of information, CYCLOPS places particular emphasis on visualising the potential uses of recyclates. We have developed a matrix that shows the potential of recycled materials in different industries, which helps users to find suitable materials for their specific requirements. In addition, data quality is emphasised, as we have found that better data can lead to greater market success. How do you assess the role of digitalisation in promoting the Circular Economy? Werner: Digitalisation is crucial for restoring the often interrupted flow of information between the players in the Circular Economy. Tools like CYCLOPS are key components that not only close information gaps, but also advance the Circular Economy as a whole by enabling more sustainable decisions. CYCLOPS was developed by SKZ, the Wuppertal Institute, GreenDelta and Cirplus. What further development opportunities do you see for CYCLOPS? Werner: In future, we could make the ecological assessment even more detailed and make more specific statements about different recyclates. The integration of user assistance systems and artificial intelligence could further improve and personalise the selection processes. An extension of the tool approach to other materials is also conceivable. Is CYCLOPS aimed exclusively at business users, or do you also see an expansion to the end consumer market? Werner: At the moment, CYCLOPS is primarily aimed at business users who are active in the Circular Economy, either by offering recycled materials or by looking for sustainable material options for their production. A direct application for end users is not currently planned, but general education about the benefits and possibilities of recyclates is an important aspect of our work. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Finally, what does the future hold for CYCLOPS? What next steps are planned? Werner: We are continuing to monitor the use and acceptance of CYCLOPS on the market, particularly in collaboration with platforms such as CIRPLUS. At the same time, the findings from CYCLOPS will be incorporated into our other research projects in order to continuously improve efficiency and sustainability in the Circular Economy. The constant further development of the tool and the integration of additional data sources are at the forefront of this. The CYCLOPS tool is freely available. How CYCLOPS partner Cirplus wants to drive the Circular Economy forward with its digital marketplace for recyclates can be read in this exclusive interview! Stephan Weiner More around Digitalisation

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  • OPC UA significantly simplifies processes

    Industry interview with Georg Kiesl, General Manager, Billion SAS OPC UA (Open Platform Communications Unified Architecture) was developed to enable communication and data exchange between machines. Copyright: Billion SAS Mr. Kiesl, why is Billion working to promote the OPC UA standard in the USA? Georg Kiesl : For us, the biggest advantage is interoperability, which enables the use of different machine types, but also different brands of the same type within a factory's digital network. This interoperability is a basic building block for many existing concepts, such as predictive maintenance - plus it is extremely important for future concepts. One single system for the entire factory, into which everything can be integrated, is a major advantage, and also the reason why we are strongly in favour of it. From our perspective, the basic framework has been established. Georg Kiesl, General Manager Billion SAS That said, you and the other players in the plastics machinery industrywill initially incur costs for your efforts. Kiesl : Yes, there are advance payments on our part, that are necessary to win our customers over. Networking machines with digital instruments as part of Industry 4.0 has been around for some time. Until now however, it has often been the case that everyone has tried to bring their own approaches closer to the customer. These are always individual implementations with individual communication protocols. By launching a standardised product, we can make it clear to customers that it will simplify their processes. It is true that OPC UA entails initial implementation efforts, but all subsequent steps are much simpler because the implementation logic remains the same. This means that the implementation costs for the second, third or fourth application are significantly lower. The manufacturers of injection moulding machines have been working on the so-called Companion Specifications for a long time. What is the current status? Kiesl : From our perspective, the basic framework has been established. There are basic Companion Specifications, plus we already have customers who are utilising them. At present, it's a matter of expanding these specifications andadapting them to individual customer requirements, but because we have the basic concept, we can already demonstrate the benefits to customers. Our major French customer Schneider Electric is very much in favour of OPC UA. For example, they are looking to connect all the machines in their factories to their predictive maintenance tools, regardless of the machine type. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Are American customers more risk-averse? Kiesl : American customers know very well that sooner or later they will not be able to avoid networking their systems. However, some aspects there are different to Europe: the market in the US is very dynamic and open to new technologies. As a result, you see a lot of technologies come and go there. That's why American customers are more cautious and don't want to jump on the first bandwagon that comes along. We have to convince customers that OPC UA will still be around in five, ten or even twenty years' time. It's a standard that makes a lot of sense, and that's why it's here to stay. There is an initial implementation effort, but that will decrease over time. In other words, the system is able to grow with little effort. Kiesl : Exactly, and even if new Companion Standards materialise that are perhaps not yet foreseeable, the server-client logic will always remain the same. If everyone uses their own individual Industry 4.0 approach, then the basic logic will be so diverse that someone who wants or needs to connect multiple brands and machine types to their network will have to start from scratch every time. With OPC UA standards, there is an initial hurdle for the implementation, after which everything is reusable: this is the main point for our American customers to consider. How important is it for Billion that American customers accept OPC UA? Kiesl : It is very important for us for two reasons: firstly, the USA is a huge sales market. On the other hand – and this is even more important for us at Billion – the USA is a significant economic trendsetter. The American influence is very strong in North, Central and South America – regions in which Billion has multiple operations. American thinking and American standards are widespread there, which is why it's important to have the Americans on board with OPC UA. If you’re really looking to create a global language for machines, you can’t bypass the Americans. Source VDMA More around Digitalisation

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  • Digital compass to sustainability: lifecycleValueCalculator analyses economic and ecological potentials

    Interview with Stefan Feldmeier, Global Product Manager, KraussMaffei Group GmbH Exclusively for K-MAG The LifecycleValueCalculator is a new module in KraussMaffei's pioneersClub customer portal. It guides you through a comprehensive calculation in 6 steps. Copyright: KraussMaffei 11.12.2023 Profitability and sustainability are not opposites – on the contrary! KraussMaffei's lifecycleValueCalculator proves it: the digital tool calculates the current status of plastics processors' products and shows them their individual potential for improvement. This enables them to increase their production efficiency and achieve their ecological goals at the same time – a symbiosis that is essential in today's world. In an interview with K-Mag, Stefan Feldmeier talks about how the tool works, its advantages and the extent to which it is a crucial tool for the future of the plastics and rubber industry.Mr Feldmeier, what prompted you to develop the lifecycleValueCalculator? Stefan Feldmeier: At KraussMaffei, we have been offering our customers tools and solutions to optimise their savings potential for a long time. The lifecycleValueCalculator was therefore developed as a further customer solution to support our customers in calculating their current actual status in production and maintenance in an intuitive way. How can plastics processors use it in their day-to-day work? Feldmeier: Our tool differs significantly from other solutions in the plastics processing industry. It enables our customers to enter their individual production parameters in order to calculate their current situation in detail and identify customised potential for improvement. This means that our customers do not have to rely on mere sample calculations, but can use their own production parameters according to their individual production conditions. This ensures a precise and customised analysis for companies to maximise their profits and achieve their CO2 targets. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) How does the lifecycleValueCalculator fit into KraussMaffei's D2 strategy (decarbonisation through digitalisation)? Feldmeier: It enables customers to optimise their sustainability through digital data processing. By calculating the individual ecological impact of production, the tool also helps customers to fulfil the increasingly stringent legal regulations and documentation requirements on ecological aspects, thereby helping them to achieve their ecological goals. In particular, national regulations such as the Supply Chain Duty of Care Act, requirements for recycling quotas, the digital product passport and indirect influences on external financing, triggered by the EU taxonomy, require a high level of transparency regarding ecological impacts. The lifecycleValueCalculator helps to meet CO2 targets and maximise profits at the same time. Copyright: KraussMaffei Are extensions or updates for the lifecycleValueCalculator already being planned in order to be able to respond to future challenges and changes in the industry? Feldmeier: We want to extend the lifecycleValueCalculator to other regions in the near future and continuously include new calculation models for products and services. We will also integrate further functionalities based on feedback from our customers in order to offer maximum added value. We will increasingly integrate the CO2 footprint into our calculations to support companies in environmentally conscious production and sustainable decisions. How do you see the role of digital tools in the future of the plastics and rubber industry, and what trends or developments should companies keep an eye on? Feldmeier: Digitalisation paves the way to sustainability by collecting, monitoring, analysing and validating data in order to initiate concrete measures for improvement. Digital service products make it possible to react proactively even before problems occur. In this way, it is possible to determine and reduce CO2 emissions (decarbonisation) and reduce costs at the same time. Elena Blume (Editorial team K-MAG) More around Software & Apps

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