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 (45)

  • Augmented Reality in the plastics industry: individualized instructions for the entire product life cycle

    AdaptAR generates instructions automatically and facilitates work on machines Exclusively for K-MAG Copyright: westend61 25.08.2022 Individualization is the trend. In the plastics industry, too, more and more individualized machines are coming onto the market. Of course, these machines also require individualized manuals with instructions tailored specifically to them. However, this is not yet a reality today. The AdaptAR project wants to change that – with the help of Augmented Reality and an app. You're operating a machine, suddenly a problem arises, and you naturally look directly in the manual – but you just can't find the right answer to your question. Does that sound familiar? This could be because the manual is not tailored to your specific product type, or because your manual is only available in paper form, making it much more difficult to look up specific information. Copyright: Fraunhofer IPT AdaptAR solves contradiction between need and reality Today, user manuals are still often published in paper form. For the most part, they are created manually – at the beginning of the product lifecycle. Subsequent changes to the product can no longer be taken into account. As a result, the information is not geared to the actual needs of users. This is precisely where the AdaptAR project comes in. Karl Lossie from the Fraunhofer Institute for Production Technology IPT – coordinator of the joint project – explains the thinking behind it: In the AdaptAR project, an app and several software components are being developed. With their help, individualized instructions are to be generated on the one hand, and on the other hand, these can be used in practice. The 5 core components of the project are: 1. Smart Service Algorithms are to be developed with which concrete instructions with step-by-step instructions can be automatically generated from a database for the respective concrete use case, for example the maintenance of a machine. 2. Digital Twin To this end, a database is to be set up in the project and a Digital Twin developed for each machine or system, which brings together all the associated order, product, process and resource data in a local database. In this way, all the information needed to create a manual is available in a standardized form. The Digital Twin is enriched with further data from connected IT systems during use. 3. Interface between human and Digital Twin in Augmented Reality (AR) Using digital devices such as tablets or smart glasses, machine operators are to be guided to an individual solution to the problem directly at the point of use. 4. Smart Service platform The platform is to enable the transformation of information from all relevant software systems for the generation of instructions for action. 5. Legally compliant design A legally compliant design should ensure the transfer of all project results. Concept for the provision of adaptive and context-specific instructions throughout the entire product life cycle. Copyright: Fraunhofer IPT Maintenance, documentation & Co. – AdaptAR in practice Copyright: Fraunhofer IPT To achieve these goals, the Fraunhofer IPT is supported by a total of 12 project partners - including DEGUMA-SCHÜTZ GmbH. This company manufactures rolling mills for rubber processing. User companies such as DEGUMA-SCHÜTZ can use the planned software in various use cases throughout the entire product life cycle. In addition to maintenance, the software can also support the assembly of the company's own products, commissioning and operation at customers' sites, and finally even the reconditioning of plants. Companies thus not only save costs for skilled personnel and travel, but also time. In addition to maintenance, the software can also support the assembly of the company's own products, commissioning and operation at customers' sites, and finally even the reconditioning of plants. Companies thus not only save costs for skilled personnel and travel, but also time. DEGUMA-SCHÜTZ GmbH also aims to improve its documentation in the project. This plays a particularly important role for the manufacturer in another of its fields of activity, the sale of used machinery. Thus, with the help of the results from the project, a high quality of documentation can be achieved for the buyers of the used machines from DEGUMA-SCHÜTZ. Less paper also means less waste and thus greater environmental awareness. Overcoming barriers thanks to AR Copyright: Fraunhofer IPT In addition, fewer downtimes and accidents occur due to improper operation of the equipment – on the one hand due to the availability of instructions that are precisely tailored to the product type, and on the other hand due to user-friendliness and specificity. For example, certain steps in the app may have an AR representation, while other steps may not - depending on the user's preference or experience. As soon as a process is completed, any changed data is also stored in the Digital Twin. Based on the history, it is always possible to see exactly what people who previously worked on the system did or changed. AdaptAR also aims to overcome any language barriers thanks to its translation function. This should eliminate another source of errors when operating plants. Martin Schulz also told us what potential he sees in AR for the plastics industry: The AdaptAR project has been running since June 2020. At the current time, all requirements have been defined and individual software components planned. The next step is to convert these components into demonstrators. The first presentable project results are expected at the end of 2022. Users should then be able to test the instructions in different use cases. The project will run until May 2023. Augmented Reality can significantly simplify service processes in the plastics industry, for example plant maintenance, and thus make them more efficient and user-friendly. This is demonstrated by the AdaptAR project. Elena Blume (Editorial team K-MAG) More around Software & Apps

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  • A digital product passport for more sustainability

    Interview with Huafeng Zhao, Strategic Product Marketing Manager – Recycling Solutions, Kautex Maschinenbau GmbH Exclusively for K-MAG Copyright: twenty20photos 21.06.2022 The EU's Circular Economy Action Plan stipulates that by 2050 all plastic packaging must be completely recyclable and consist of at least 70 percent recycled material. The majority of plastic waste still ends up in landfills or incinerators – in the worst case, in the environment. Huafeng Zhao. Copyright: private In our interview with K-MAG, Huafeng Zhao talks about how the R-Cycle system is going to achieve the zero-waste target in the future circular economy. Mr. Zhao, you are part of the R-Cycle initiative. What goals are being pursued there? Huafeng Zhao: R-Cycle enables high-quality plastics recycling by identifying recyclable packaging as such and then separating it. In the past, we didn’t have a proper data management system like R-Cycle to support the plastic circular economy. Therefore, about 19 percent of plastic waste worldwide go into incineration, 50 percent ends up in landfills, and even 22 percent has been found directly in our environment. Only about 9 percent is recycled und reused for second-life product. For us, plastic is the new gold, we must help to educate the people to understand the values behind plastic products and also to understand how we should treat plastic in a right way. How can this goal be achieved? Zhao: We are working on an open and globally applicable tracing standard to ensure the traceability of recyclable packaging along the entire value chain. All recycling-relevant information – like material type, color, MFR, food or non-food, PCR/PIR content and so on – can be recorded by the machine control system during the production and transferred all these information in the form of the digital product passport. The tracing technology behind R-Cycle is based on GS1 standards. It is accessible to any production facility, from plastic film injection molding or extrusion blow molding machines through to converting, printing, filling, sorting and recycling machines. To retrieve the stored information, a marker – for example a QR or digital watermark code – is applied to the packaging. At the end, R-Cycle will improve the efficiency of the entire value chain, so that we will get more and more high qualified recycling materials in the future and ensure the traceability of plastic packaging along their whole life cycle. The R-Cycle Community's goal is to find a cross-industry solution to achieve a zero-waste closed loop recycling system for plastics. Copyright: R-Cycle In this context, you have also launched pilot projects. What are they about? Zhao: In our first pilot project, we have developed two 1-liter bottles made of two different HDPE materials from Braskem. One variant is made of a bio-based PE from sugar cane. The second variant is made from recycled PE. In both bottles, we have implemented a QR code as a marker that can be scanned even by the camera of your mobile phone. In this way, all recycling-relevant information which we have via our machine has been stored in the database. We have implemented digital watermark as new marking technology in our second pilot project. These digital watermark codes, which are almost invisible to the human eye, have been integrated into the entire surface of the packaging label, which are also be linked to the R-Cycle database platform. In this way, waste sorting systems with an appropriate system can sort the plastic waste in a much more precise way. Additionally, these codes can be read on any smartphone by each end-user by simply using the Digimarc app. Kautex’s know-how of the pilot project is development of the data collection system “R-Connector”, which functions as link and interface between the extrusion blow molding production and the cloud-based R-Cycle platform. By using the “R-Connector” in Kautex production solutions, all necessary production data will be recorded, analyzed, and uploaded to the R-Cycle server in real time. A digital product passport such as a QR code on bottles or cans could contribute to more efficient recycling of plastics. Copyright: twenty20photos You are working with many partners in the pilot project, but also generally at R-Cycle. Why do you think such collaboration is so important? Zhao: In our pilot project, following our BeOne culture, we are working with raw material manufacturer Braskem, packaging manufacturer Kautex Textron and recycling specialist Morssinkhof Plastics. A system like R-Cycle will only work in the end of the day, if all the participants along the whole value chain working on one tracing standard. That is the reason why the R-Cycle community is a cross-industrial cooperation with companies, which are coming from different application areas in the plastic industry. The R-Cycle Community is open to all companies, organizations or individuals who have a legitimate interest in the topic of future circular economy for smart added value plastic packaging. Here we want to highlight that Reifenhäuser is the founder of the R-Cycle system and Community. We as Kautex Maschinenbau are so glad to be one of the "first movers" in the R-Cycle Community. And our community is still keep growing with more and more new partners. The R-Cycle system will only work if all the participants along the entire circular economy are aligned to take their responsibility and working together to develop one global tracing standard. Only through this way, everyone can get benefit from the future circular economy. Elena Blume (Editorial team K-MAG) More around Software & Apps

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  • PRISM – a data platform for the circular economy

    Interview with Manish Chawla, Industry General Manager, Energy, Resources & Manufacturing, IBM Exclusively for K-MAG Bild: PantherMedia/Andriy Popov 06.04.2021 In mid-December, U.S. IT company IBM announced it had joined the Alliance to End Plastic Waste. Together, they are designing the PRISM platform – a unified ecosystem of NGOs, the plastic value chain participants, communities, regulators, and any organization looking to deploy and improve waste management decisions and programs. In an interview with K-MAG, Manish Chawla talks about the added value of the new platform, important steps on the way to achieving the circular economy and what contribution IBM is making to greater sustainability. What made you join the Alliance to End Plastic Waste? Manish Chawla: IBM has a long-standing commitment to the environment, dating back to as early as 1971 when IBM published its first corporate environmental policy statement. Today, IBM remains committed to good stewardship of the planet's resources and has made significant progress in managing waste, conserving energy, using renewable electricity, and reducing carbon dioxide emissions. In addition to our corporate commitments, we also have a legacy of helping clients use technology to solve complex sustainability challenges. You are now also developing such a solution together with the Alliance in the form of the "PRISM" (Plastics Recovery Insight and Steering Model) platform. What is the goal behind this? Chawla: There are so many complex environmental – as well as business – challenges that persist today simply because data generated is not properly shared, interpreted, or used. Right now, most data on plastics, plastics waste, and waste management infrastructure is contained in silos, which means no one has a full picture of what is going on. There are several excellent – but independent – initiatives underway with NGOs as well as within the private sector; however, there is an opportunity to bring this data together and further fill in the gaps in a unified system that will allow for multi-dimensional analysis – the whole really can be greater than the sum of its parts. As an open platform, PRISM can bring these data sets together so everyone better understands the full plastics ecosystem and can target interventions that will have the biggest impact where they are needed most. Using PRISM, organizations will be able to identify the data gaps and commission the development of data sets to ensure we have the full picture. We look forward to working with diverse institutions including universities and other institutions to capture those critical data sets. Bild: PantherMedia/lightsource Another key challenge which we hope to tackle with PRISM is a common approach to validating and harmonizing data around plastic waste, ensuring accuracy and transparency. Last year we published a study that found data scientists spend only 20 percent of their time on data analysis – while the remaining 80 percent goes to finding, cleansing and organizing data. Our approach to PRISM is intentional to reverse that from the onset by using IBM Cloud, which can build a platform with different data formats and data definitions that integrates all this knowledge, with data standardization and a data governance framework. This allows PRISM to act as an open, scalable platform to bring together these data sets so everyone can target interventions that will have the biggest impact where they are needed most. What is the current development status of the platform? When is it expected to be usable? Chawla: Right now, we are still developing and working through data governance for PRISM; however, the intent is to integrate AI capabilities to aid in data analysis down the road. We are in the early stages of development, with a beta version in place that will shortly be made available to select external stakeholders including NGOs, inter-governmental organizations, and our member companies for testing and evaluation. We are aiming for a wider release to a broader group later this year and will share more in coming months. What is IBM's contribution to more sustainability in the plastics industry or the realization of the circular economy? Chawla: As said, IBM regularly works with clients to use technology to solve complex sustainability challenges. Specific to plastics and the circular economy, in 2019, IBM created a new technology called VolCat , a catalytic chemical process that can turn polyethylene terephthalate (PET) into a renewable resource. VolCat uses a benign organic catalyst to selectively digest PET back to its monomer constituents. After purification, the monomer can easily be re-polymerized to form new PET. The cost-effective and sustainable innovation is capable of breathing new life into old plastic. We predict that technology such as VolCat could be adopted around the global to combat plastic waste. We are beginning plans to kick-off the next phase to commercialize the technology. Elena Blume (Editorial team K-MAG) More around Software & Apps

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  • Material development: getting there faster with co-pilot AI

    Interview with Josh Tappan, Director of Marketing, Citrine Informatics Exclusively for K-MAG Source: PantherMedia/Kiyoshi-Takahase Segundo 24.08.2021 We live in fast-paced times. This is reflected in consumer preferences. In addition, climate change is creating a rapidly changing regulatory landscape for chemical and materials companies. They have to adapt quickly. But the thorough research, development and commercialization of new materials can be lengthy. Artificial intelligence can speed up this process. Josh Tappan, Citrine Informatics. Source: private In an interview with K-MAG, Josh Tappan talks about the Citrine platform , how artificial intelligence (AI) can help companies develop materials and make the plastics industry more sustainable. What is the purpose of your Citrine platform? Josh Tappan: The Citrine Platform combines smart materials data infrastructure and AI to accelerate the development of next-generation materials and chemicals through an iterative, AI-guided workflow – which has demonstrated the ability to reduce R&D time by 90+ percent, optimize our customers' product portfolios, and codify research IP, which enables its reuse and prevents its loss. This is what the AI-driven product development workflow looks like. It makes manufacturing high-performance, sustainable materials 50-75% faster than traditional methods. Source: Citrine Informatics Who is the IT solution aimed at? What does it look like to work with the platform? Tappan: The Citrine Platform is aimed at product development and application engineering organizations in the materials and chemicals and discrete product manufacturing industries. Customers interact with our platform through a web-based user interface or a python-based API. A typical workflow for our customers is: Import and structure historical data into a graphical format (Graphical Expression of Materials Data, or GEMD) that visually represents the context of a material from procurement to final product. Define a "design space" on the platform, which is the set of possible candidates. Customers define this based on their scientific domain knowledge and manufacturing or supply chain constraints. Train an AI model (with as few as 20 rows of data) to predict properties or performance targets of interest for new materials candidates. The AI model identifies new materials and/or processes within the design space that are likely to hit the performance/property objectives. Our customers synthesize and test the most promising candidates in the lab based on the AI-generated predictions and their knowledge of the problem at hand. If the new candidates hit or exceed our customer's objectives, they proceed to scale-up and commercialization. If candidates do not hit some or all of the customer's objectives, they incorporate this data back into the model, improving the models predictions, and increasing the likelihood that new candidates will meet their objectives. The data structure is tailored to the needs of the industry and captures the entire wealth of physical experiments. Source: Citrine Informatics What role does AI play in material development? In what ways can it make work more efficient? Tappan: We see it AI a co-pilot that enables product developers, scientists, and engineers to do their jobs better. Materials development problems are highly complex and multi-dimensional, so it's impossible for any human (or team of really smart humans) to evaluate all of the possible solutions and materials that might meet their goals in a reasonable amount of time. With our platform and an AI-guided product development workflow, our customers have accelerated the rate at which they develop new materials by 90+ percent compared to traditional methods. On top of that, as scientists start to incorporate their expertise into the modeling process, new scientists and adjacent teams can begin to reuse these digital assets to get a jumpstart on new projects and product development initiatives. This both decreases the "ramp-up time" for new projects, and ensures that senior scientists are sharing their knowledge across the team and preventing knowledge loss as veterans begin to retire and new scientists enter the workforce. This domain knowledge can take a number of forms on our Platform from well-structured graphical datasets, "features" or "descriptors" of physical phenomena and known processing relationships that can be used as inputs to a machine learning model, design spaces that define the set of constraints and objectives for specific applications, and reusable AI models. Exhibitors and products around raw materials Thermoplastics Thermoplastic elastomers Resins and compounds Rubbers Starting materials, intermediate, polymerisation auxiliaries Where there is AI, there is also a lot of data. What about the protection of this data? Tappan: Security is especially important when dealing with product development data. At Citrine, we take a holistic view of security, ensuring that we have mechanisms to protect physical, network and application components of the platform and our customers' data, and we couple with transparency about our security compliance best practices. I'd recommend that customers vet vendors' (and their internal) security protocols and safeguards to ensure that they have the best possible physical, network, and application security practices and protections in place. What further developments are conceivable in the future? Tappan: In the short term, I think we'll see a lot more companies using AI, simulation, and experimental results in concert to rapidly design new materials, chemicals, and molecules. We've also invested in capabilities to unlock materials design as a new degree of freedom in part-level simulation for discrete product manufacturers. By leveraging materials informatics within part and system-level simulation tools, product developers can use part performance requirements to drive material development rather than designing around materials constraints or limiting themselves to materials available in supplier catalogues. The machine learning models learn from you and your experiments. Expertise and data are used to predict performance. Source: Citrine Informatics In the medium-term, we'll start to see more advances in polymer informatics. Right now, AI works well with formulations, small molecules, and inorganics, but we're seeing the field of polymer informatics rapidly evolve. We recently participated in a workshop hosted by MI on harnessing big data to develop new polymers and are actively working on advancements in the field of polymer informatics. In the longer-term, we will see "self-driving" labs adopted in industry. There have been recent advances in academia in combining AI, robotics, simulation, and laboratory automation software in a closed-loop guided workflow to autonomously discover and develop new materials. Many of these pieces already exist in isolation in commercial labs, so it's natrual for companies to invest in combining these capabilities to develop commercial "self-driving labs" in the future. Design spaces define useful and feasible possibilities. This results in a million possible experiments worth considering. Source: Citrine Informatics To what extent can digitization contribute to greater sustainability in the plastics industry? Tappan: A more sustainable plastics industry is critical for the future of our planet and humanity, and digitalization plays a crucial role in this sustainable transformation. Recently, we've been excited by what we're seeing in the market, and believe that companies are making significant investments into making their sustainability goals a reality. Higher performing products alone will not meet our global environmental and societal needs. However, sustainable products that do not perform as well as conventional alternatives present business problems for producers (we commonly refer to this as the "paper straw problem"). Our customers have utilized AI-guided product development as a tool to optimize for both performance AND sustainability, whether it's adapting existing products to use more sustainable ingredients and feedstocks, optimizing manufacturing processes to decrease carbon footprint, energy or water usage, or designing high-performing plastics that are recyclable or biodegradeable. Elena Blume (Editorial team K-MAG) More around Artificial Intelligence

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  • EREMA: "PredictOn:Drive", a new tool for predictive maintenance

    PredictOn:Drive enables predictive maintenance of all main drive trains and, for PET recycling plants, also the vacuum pump stations. Copyright: Erema 04.11.2022 Real-time visualisation of process and machine data holds great potential for the circular economy as a whole and for recycling processes in particular. At K 2022 EREMA launched "PredictOn:Drive", a predictive maintenance application for its recycling machines. The app can be used to monitor the condition of the main drive trains and vacuum pumps during operation to predict when maintenance needs to be performed next. The machine operator benefits from improved scheduling of maintenance work, shorter downtimes and lower costs. "PredictOn" is the name of EREMA's new predictive maintenance package. At K, the recycling machine manufacturer presented "PredictOn:Drive" – the first tool in this package – as a solution for monitoring and predicting maintenance requirements for all main drive trains and vacuum pump stations on PET recycling machines. Behind this is an ingenious modular measurement and sensor system for real-time data acquisition and storage that is used for machine condition evaluation as well as for advanced analysis of damage location and damage spread while proposing possible countermeasures. That is how the machine provides data to visualise the condition of the plant and enable predictions on the maintenance work necessary. "The big benefit of recognising maintenance requirements and anomalies on critical components in good time is that machine operators can respond before a problem occurs. Deploying service personnel and obtaining spare parts can be better planned using predictive maintenance and leads to higher plant availability and lower costs compared to routine or scheduled preventive maintenance. That is because we only intervene when a problem has been identified," explains Florian Schieder, who is responsible for EREMA’s development and innovation planning. EREMA currently equips all large-scale INTAREMA®, VACUREMA® and VACUNITE® plants featuring extruder diameters larger than 160 millimetres with the necessary measuring systems for drive train monitoring. Existing plants can also be retrofitted with these systems. In a next expansion stage, smaller plants as well as machines from sister company PURE LOOP are to follow. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) BluPort® – the digital customer platform for real added value BluPort® online platform puts together in one place a collection of intuitive and user-friendly service and data processing apps that support our customers in quality control and, as a result, increase machine performance. Copyright: Erema EREMA makes this data available to its customers in its own maintenance app on the BluPort® digital customer platform, which bundles all digital assistance systems. The platform can be accessed via PC and mobile devices and offers a comprehensive suite of service and data visualisation apps that help plant operators control quality and improve machine performance. "With our apps, we want to accompany customers and their machines through all phases of the machine life cycle, starting with the purchase decision through to operation, maintenance and services, and eventually to buy-back of the used equipment years later. And all that with just one login," says Christoph Krump, who heads the Service business unit at EREMA. Using the Project Cockpit app, customers are already involved in the creation of their new machine. With this they get insights into the status of project planning, and overview of all features and a list of all the relevant contact persons in case questions arise. The Key Performance Indicators app is very popular with customers because they can use it to call up the most important data, such as throughput trends and the energy consumption of their machines, all displayed in an intuitive dashboard. Long-term archiving, a booking app for training courses and workshops, and a spare parts shop are examples of other useful tools provided by BluPort®. From a technical standpoint, all EREMA machines ordered within the last 3 years are already equipped for use with all of these assistance systems. The app offering is constantly being expanded. The basic package is free of charge. Customers who purchase the Smart Service Package get the full version including extra content. Source Erema More around Software & Apps

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  • Covestro to Launch Automated Laboratory for Coating and Adhesive Formulation Development

    Digitalized research infrastructure combines robotics, data intelligence and automation to accelerate formulation processes Fully automated workflows and digitalized processes enable high-throughput testing and data generation at Covestro’s new lab. Copyright: Covestro 21.04.2025 Covestro is set to open a state-of-the-art automated lab in 2025 to optimize coating and adhesive formulations. With a focus on digitalization, circular materials, and customer-specific testing, the lab aims to run tens of thousands of tests annually—24/7, driven by AI and smart robotics. Accelerating Material Innovation Through Automation Manufacturers of coatings and adhesives face growing pressure to innovate quickly, improve efficiency, and meet sustainability and regulatory standards. A key success factor: the right binders and crosslinkers . To support this, Covestro will open a fully automated laboratory in 2025 dedicated to developing and optimizing formulations. "With our automated laboratory, we can work together with our customers on the future of coatings and adhesives. Because it operates almost completely autonomously and learns from our existing knowledge and data lake as well as newly generated data, it makes the process of optimizing and developing formulations many times more efficient and precise," says Thomas Büsgen , head of the laboratory. "This allows us to optimize existing formulations faster or even develop completely new formulations for and together with our customers. We can say: We are reaching a new level of modern research." In Covestro’s new automated laboratory, robotics support the preparation and testing of coating and adhesive formulations. Copyright: Covestro Testing Formulations with Covestro Binders and Crosslinkers The lab will focus on formulations based on Covestro’s binders and crosslinkers—key components for ensuring desired material properties such as hardness, adhesion, gloss, or durability. These formulations typically consist of 7 to 15 ingredients, resulting in a vast number of combinations. The use of computer-aided design and automation now makes it possible to run extensive test series efficiently. "Our new automated laboratory gives us more possibilities for testing formulations. It relieves our specialized laboratories of their standard tasks and can analyze samples more systematically," explains Martin Merkens , Head of Sales & Market Development EMLA in Covestro's Coatings and Adhesives business entity. "This will particularly help us in the area of circular economy: Alternative raw materials, for example bio-based or recycled materials, can be tested faster and evaluated for their properties in the final product." Technical Highlights at a Glance 24/7 operation with automated workflows Tens of thousands of tests annually Integration of water- and solvent-based 1K and 2K systems Climate-controlled testing environments AI-supported design and validation of test series Connection to specialized labs for extended testing Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Source Covestro More around Digitalisation

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  • Enhanced Efficiency with Advanced Automation Software

    How a retrofit inspection system transformed a century-old packaging producer 23.12.2024 Semoulin Packaging, a Belgian family business specializing in paper bags and printed reels, is embracing cutting-edge automation to improve quality and consistency. The integration of W&H's advanced inspection software is setting new standards in production reliability and efficiency. Innovation meets tradition With over 100 years of expertise, Semoulin Packaging has consistently modernized its operations to maintain its reputation for high-quality printed reels and paper bags. Founded in 1910 in Hainaut, Belgium, the company combines traditional craftsmanship with state-of-the-art solutions to meet customer needs. Its long-standing partnership with Windmöller & Hölscher (W&H) and its subsidiary Garant reflects a commitment to innovation and reliability. The role of advanced software in production Advanced automation systems like W&H's VISION enhance production quality and efficiency, supporting manufacturers in meeting modern industry demands. Copyright: W&H W&H’s VISION system offers a comprehensive software-based solution for inspection and automation, tailored to the needs of modern packaging producers. Key features include: Centralized Software Control : Operators benefit from an intuitive interface that integrates press and inspection controls for faster, more efficient setups. Real-Time Insights : By analyzing data flow between press functions and inspection modules, the system enables precise defect detection and root cause analysis. Customizable Capabilities : Modules like BARCODE CHECK and PDF CHECK provide flexible options to enhance production workflows. Global Service : W&H offers robust technical support to ensure smooth operation worldwide. Mathieu Dehon, Production Manager at Semoulin Packaging, highlighted the advantages: “It is a very intuitive system, easy to handle for the operators and we clearly see the advantage of one provider offering a completely integrated system.” A seamless retrofit process Semoulin recently extended the use of VISION to an older MIRAFLEX flexo printing press. The process, completed in under two weeks, included the installation of web monitoring and error detection features, further improving operational efficiency. To harmonize workflows, Semoulin also implemented EASYSET and EASYREG HD modules, enabling consistent setups across their equipment. Key takeaways Software-Driven Transformation : Improved job setup times and defect detection with integrated software. Adaptability : Quick and seamless retrofitting of existing machinery. Sustainability : Enhanced quality control ensures minimal waste during production. By integrating advanced automation software, Semoulin Packaging demonstrates the potential of modern technology to elevate traditional manufacturing practices. Source Windmöller & Hölscher More around Digitalisation

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  • AI Boom Fuels Demand for High-Performance Data Cables

    Next-gen data cables require next-level process control – SIKORA’s technology ensures extrusion quality under growing demands. Data cables must be precisely standardised today due to AI performance. Copyright: envato 16.05.2025 As global investments in AI data centers surge, so does the demand for high-performance data cables. SIKORA provides highly precise measuring technology to ensure flawless extrusion processes, helping manufacturers meet new quality standards in real time. AI Data Centers Drive New Cable Standards With massive investments in AI infrastructures like Stargate in the U.S. and DeepSeek in China, the need for reliable high-speed data cables is growing fast. These cables must transmit several gigabytes per second over long distances, making flawless performance a must. In this new context, short-term fluctuations in cable geometry or insulation quality can lead to signal reflections, drastically shortening the usable cable length. Precision Over Averages: Why Measurement Matters Previously, it was enough to keep the cable diameter within the nominal value. Today, even minimal deviations can compromise data transmission. To meet these heightened demands, continuous and precise monitoring of the extrusion process is essential. SIKORA’s measuring systems stand out by providing single value accuracy , not smoothed averages, a decisive advantage when it comes to identifying critical variances. Key Parameters That Influence Cable Quality To enable long-distance, high-speed data transmission, cable producers must tightly control the following characteristics: Diameter: Deviations impair performance. Out-of-roundness: Every irregularity impacts signal stability. Conductor eccentricity: Affects insulation integrity. Foaming level and capacitance: Determine electrical properties. Pair spacing consistency: Prevents reflections. Exhibitors & products around digitalisation CAD systems Simulation software Quality assurance software (SPC/SQC) Maintenance software Equipment & software for manufacturing execution system (MES) Monitoring in Real Time With systems like LASER , CENTERVIEW , and CAPACITANCE , SIKORA delivers real-time, high-precision measurement of all relevant values. These tools do not rely on interpolated averages but instead register each single value with utmost accuracy. A built-in watchdog function immediately signals when limits are exceeded, allowing for quick intervention and long-term quality assurance. Future-Proof Production Requires Live Process Control Manufacturers aiming to supply next-generation data infrastructure, from AI clusters to industrial networks, need technologies that detect and react to fluctuations instantly. SIKORA’s measurement technology not only meets these requirements but offers a competitive edge in quality assurance and customer satisfaction. Source SIKORA More around Digitalisation

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  • Reifenhäuser Wins German Design Award for New Machine User Interface

    Consistent, intuitive HMI supports efficient operation across extrusion lines Copyright: HMI Project 17.11.2025 The Reifenhäuser Group has been awarded the German Design Award for its new human-machine interface (HMI) at K 2025. The interface enables unified and user-friendly operation of blown film, cast film, and nonwoven extrusion lines—supporting efficiency, usability, and digital transformation in plastics processing. Consistent Interface Across All Lines Reifenhäuser showcased the new HMI at its open house event held during the K trade fair on its new EVO GEN3 and EVEREX blown film and flat film lines. With the launch of the new company-wide user interface , the Reifenhäuser Group has standardized the operation of its blown film, cast film, and nonwoven lines. The HMI was designed to make machine operation more intuitive and efficient—an important contribution amid skilled labor shortages. The new interface offers a consistent operating logic and a uniform look and feel across all lines, helping operators become familiar with different machines more quickly and operate them more reliably. The Reifenhäuser booth at K 2025. Copyright: Messe Düsseldorf/ctillmann Focus on Usability and Efficiency The system enables settings in just two clicks, features customizable dashboards, and provides a clear start screen that ensures full process visibility. The design includes : A responsive touch interface Visual guidance using colors and symbols Supportive assistance systems for process safety Developed in collaboration with HMI Project, the system was designed using a user-centered approach and validated through usability testing. Scalable and Future-Proof Thanks to its modular and scalable structure, the HMI can be easily adapted to various machine types and extended to future lines. This flexible design enables a consistent user experience and facilitates the implementation of digital production strategies. Recognized by the German Design Award The German Design Award has been presented by the German Design Council since 2012 and honors innovative achievements in product and communication design. The Reifenhäuser Group’s HMI convinced the jury in the category “Excellent Product Design – Human-Machine Interface,” demonstrating the value of user experience and interface quality in modern machine engineering. Source Reifenhäuser Group At a glance The Reifenhäuser Group has won the German Design Award for its new human-machine interface (HMI), designed for use across blown film, cast film, and nonwoven extrusion lines. The interface enables intuitive operation with a consistent look and feel, supporting efficiency, usability, and digital transformation in plastics processing. More around Digitalisation

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Topic areas in K-Mag

Sustainability

Sustainability

Digitalisation

Digitalisation

Machinery & Production

Machinery & Production

Raw materials

Raw materials

Science

Science

People

People

Plastics in Practice

Plastics in Practice

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