Plastics in Practice

Plastics have become indispensable in many sectors: packaging, transport, medicine, the home, construction and much more. In this section, you will find numerous articles on the use of plastics in various contexts.

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Results (110)

  • From Imperfection to Innovation: How Digital Materials Support Sustainable Design

    Nicolas Paulhac X CLD Exclusively for K-Mag Copyright: Adobe, 2025 – All rights reserved Chris Lefteri Hi Nicolas, could you introduce yourself and your role at Adobe please? Nicolas, before we dive in, tell us a bit about yourself and what you do at Adobe. Nicolas Paulhac I’m the Director of 3D Content at Adobe Substance. My background spans industrial design and CMF (Color, Material, Finish), where I focused on how products are made and how various industrial processes shape material transformation. At Adobe Substance, we offer a suite of five specialized applications for material authoring, texturing, and staging—empowering 3D artists and designers across diverse industries to create digital materials, apply them to products, and visualize their designs. My role involves leading content production within these apps and curating ready-to-use assets for our Substance 3D Assets library, which provides the foundational elements creators need for their 3D projects. Copyright: Adobe, 2025 – All rights reserved Chris Lefteri Perfect! And how do you bring the world of real materials into the Adobe software? Nicolas Paulhac Digital material creation can be approached in two main ways, each offering unique advantages. You can scan a real physical surface or create textures fully digitally. Scanning, involves capturing real-world materials using a material scanner. It ensures high fidelity and precision by generating texture maps that reflect how the material reacts to light through key properties such as color, glossiness and surface relief. It’s ideal for replicating materials with accuracy and realism. Materials can also be built entirely from scratch using procedural tools. This method offers maximum flexibility and control, enabling creators to define every aspect of the material’s behavior and appearance without relying on physical samples. These methods are not separate but complementary to each other. Designers can start with a scanned material and then apply additional effects—modifying color, adding surface details, or introducing patterns not present in the original sample. This approach allows for creative freedom while maintaining a strong link to the physical reference, essentially crafting a personalized “material behavior”. At Adobe Substance, we utilize both methods to produce textures. Each material in the 3D Assets library is a living asset designed to be personalized. Each material, through its exposed parameters that users can modify, acts as a mini-library capable of generating infinite variations of itself—whether in terms of color, surface grain, glossiness, pattern, and more. For CMF designers specifically, it can act as a kind of digital fab lab. This empowers artists and designers to build tailored digital materials that are both expressive and production-ready by preserving coherence with real-world material behavior. Copyright: Adobe, 2025 – All rights reserved Chris Lefteri And that Fab Lab is relating back to the way the materials, in the real three-dimensional sense, get processed? Nicolas Paulhac When there is a visual impact of the process on the surface, which is very often the case, yes. We begin by studying the visual properties of physical samples to reproduce them as faithfully as possible. But we don’t stop there. We analyze the forming processes—examining how each production step influences the final look and feel of the material. By connecting these insights to finishing techniques, we can introduce meaningful customization parameters into the digital material. It’s a way of embedding process awareness into the material itself, making it not just a visual replica but a customizable digital asset. Copyright Video: Adobe, 2025 – All rights reserved Chris Lefteri So, you must have a fantastic physical materials library? Nicolas Paulhac We collect samples, indeed—but not just physical ones. Our references span a wide range of formats, including images, mood boards, color palettes, and technical documentation. Depending on the material or process we aim to recreate, we have collaborated on specific collections with material suppliers, consulted existing resources, or studied real products. In some cases, we even fabricate custom samples specifically to create digital materials. This allows us to capture larger surface areas or to isolate individual stages of a finishing process—creating each stage separately. By doing so, we gain precise control and realism when digitally reconstructing the material. Copyright: Adobe, 2025 – All rights reserved Chris Lefteri And how do you stay updated with new materials, technologies and processes? Nicolas Paulhac Well, it involves staying up to date with trends in product and CMF design. We approach it with a segmented lens—by industry and product category. We observe how materials evolve across domains to ensure our digital content remains relevant and forward-looking. When it comes to manufacturing, we engage with model makers and material engineers, especially when we need to understand how things are made. Sustainability trends are very interesting to us. Eco-designed materials are part of our area of interest— even if, for now, our focus is on making their digital twins visually realistic. We believe digital tools have a vital role to play here—supporting sustainable innovation at multiple levels. A great example is our collaboration with Chris Lefteri Design for the 3D Assets library, which attempts to show how digital materials can support early-stage creative exploration. Whether it’s advanced technologies like reactive surfaces—thermo-bimetals or auxetics—the digital medium allows us to mimic desirable finishes and potential applications long before physical prototypes exist. Similarly, our visual explorations around plastic injection processes for the K-Show enabled us to pre-visualize new effects linked to the use of fillers. This opens creative opportunities to make imperfection and transformation desirable—turning technical constraints into expressive material qualities for design. Copyright: Adobe, 2025 – All rights reserved Copyright: Adobe, 2025 – All rights reserved Copyright: Adobe, 2025 – All rights reserved Chris Lefteri Yes, this most recent collaboration was looking at sustainability as a new way to realise the surface or composition of a material and to somehow represent that digitally. Was it a challenge for your team to work on our collaboration, or generally on dealing with unperfect materials? Nicolas Paulhac It was a truly stimulating challenge. The brief on composite plastics gave us the opportunity to explore not only how to visualize these effects with realism, but also how to parameterize each technical attribute to animate transitions between different surface states. It’s a perfect example of what I mentioned earlier: building each effect digitally and procedurally, then combining them into a cohesive material experience. One of the key challenges was controlling the flow effect when mixing different components—capturing realistic dispersion patterns, the kind of surface visuals that emerge as fillers propagate and accumulate progressively. This type of work shows how digital materials can go far beyond static textures — they become dynamic, expressive tools for storytelling in CMF design. Copyright: Adobe, 2025 – All rights reserved Chris Lefteri So would the user of the software be able to control this level of tunability, in terms of color, movement and flow of the material? Nicolas Paulhac Yes, users will have control over most of these aspects. Of course, there are the basic parameters—like color and glossiness—that come standard with every material. But in this case, the user can also control the size and amount of filler added into the formula, and adjust the parameters that influence distribution, density, and growth. These changes directly affect the resulting patterns, giving the user the ability to shape how the material evolves visually. Chris Lefteri Are you seeing more industries adopting and engaging with digital materials outside the traditional ones of automotive and product design? Nicolas Paulhac Yes, we’re definitely seeing a wide range of industries embracing digital materials beyond the traditional domains of automotive, architecture, and product design. Industries such as fashion and consumer packaged goods, to name a few, are increasingly adopting digital solutions—not just for the product itself, but across every aspect of the design and visualization process. For example, even the contents of a package now need to be visualized with realism. This shift opens new opportunities for designers to streamline workflows, enhance visualization, and maintain consistency between digital and physical outputs. It’s largely driven by the need for faster iteration, cost reduction, sustainability goals, and the expanding role of digital twins—from early-stage development to marketing visualization. Copyright: Adobe, 2025 – All rights reserved Chris Lefteri Are you saying that individuals are using the software to develop food? Nicolas Paulhac Yes, it’s connected to the design. It also plays a key role in accelerating the overall process. It helps bridge design and production with the marketing phase, allowing products to be showcased earlier to consumers. This is a major advantage of using 3D: it enables visualization at an earlier stage, in a faster and more cost-effective way compared to traditional methods like photo shoots. Chris Lefteri I was actually thinking of how chefs could use it to develop their recipes or food. Because a lot of this high-end food is very visual, it is more about the Instagram image than the food itself. So, chefs could use it to design texture, patterns or effects for instance? Nicolas Paulhac I believe that’s one of the opportunities as we look ahead. A good example could be cosmetics—how do you accurately represent what comes out of the tube? Oils, serums, and other formulations need to be visualized realistically for marketing purposes. So why not use the digital medium to explore creative iterations in terms of design? It opens up new possibilities for visual storytelling and early-stage concept development, even before a physical prototype exists. Chris Lefteri And, for example — dare I say — even something like skin? Nicolas Paulhac This is actually a well-established practice in the world of games and film, known as “character art,” where specialized artists focus on texturing human and non-human skin—whether realistic or stylized. Thanks to the level of realism we can now achieve, new opportunities are emerging in other fields like Medical and healthcare. Being able to visualize not just skin but full anatomy in high detail is proving valuable—for example, one of the applications is training medical staff with virtual surgeries. Copyright: Adobe, 2025 – All rights reserved Chris Lefteri Very interesting. Also, you now have the more futuristic imagery which doesn’t even relate to a physical product – it is completely imagined. How do you approach this? Nicolas Paulhac A large part of the materials we create is dedicated to the game and VFX industries, where expressiveness and realism are key. The finality may differ across design disciplines but actually, the approach of creation isn’t so different. Whether the material is real or imagined, it still needs to tell a story. It’s about crafting what makes the material visually credible to the eye. We all go through the same instinctive reactions when we see a surface for the first time: is it soft or hard, reflective or matte, smooth or textured? These visual cues are essential to conveying emotion and materiality—how something is made, what it’s made for, and what it could inspire in terms of application. Substance digital materials are based on PBR—Physically Based Rendering—which means they accurately simulate how a surface interacts with light. With the Substance 3D applications, creators can design fully digital materials in a hyper-realistic way while maintaining control over key visual properties that matter in their field of expertise. Copyright: Adobe, 2025 – All rights reserved Chris Lefteri How do you see the use of these digital materials and tools evolving in the future? Nicolas Paulhac Looking ahead, I believe digital materials and tools will become even more central to how industries design, validate, and communicate products. The goal isn’t to position physical and digital materials as opposing forces in product creation, but rather to explore how they complement each other in the design process. By doing so, designers gain more creative freedom to visualize and communicate a design intention. Digital twins will evolve into more dynamic and interconnected systems, enabling seamless transitions between virtual and physical workflows like behavior simulation, real-time feedback loops and predictive design. As sustainability becomes non-negotiable, digital materials will play a key role in reducing waste, supporting more confident decision-making earlier in the process. Chris Lefteri My final question is, going back in time now, what’s your favourite material memory from childhood? Nicolas Paulhac One of my favorite material memories from childhood is leather. My grandfather owned a small leather goods shop, and I spent countless hours watching him shape and repair leather bags. Observing the process—the way the material responded to heat, pressure, and tooling—sparked my fascination with how things are made. It was during those moments that I developed a deep interest in the transformation of materials, not just for their aesthetic qualities but also for their performance and surface effects. That early exposure continues to influence how I think about material design today. Author: Chris Lefteri | K-Mag Chris Lefteri is a materials expert, author and industrial designer. Since 2006, he has been advising companies worldwide at the interface of materials innovation, CMF and design strategy. His books and lectures shape the global discourse on the conscious use of materials in design and industry. In K-Mag, he writes about the role of materials as drivers of sustainable product innovation. More around Plastics in Practice

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  • Plastics in action: The Invention of Rainwear

    From Rubber to Gore-Tex: How Synthetic Materials revolutionized Rainwear Exclusively for K-Mag 26.11.2025 18,000 invisible guards per square centimeter It's familiar: it's drizzling in the morning, you grab your rain jacket or raincoat. After eight hours of commuting, meetings and errands, you're still dry - and not just on the outside. No clammy skin, no sweating. But how exactly does this actually work? The answer lies in the textile coating or membrane: a Gore-Tex membrane in a modern rain jacket has around 1.3 billion microscopically small pores per square centimeter. Each one is 20,000 times smaller than a raindrop, but 700 times larger than a water vapor molecule. This is not magic - this is material science. And there is a 200-year history of chemistry behind it, in which foul-smelling tar was turned into high-tech textiles. The man who clamped cotton between rubber Scotland, early 19th century . The Scottish physician and chemist Sir James Syme experimented with dye production and obtained a by-product from coal gasification: Coal Tar Naphtha , a solvent that does not mix with water. This substance aroused the interest of Charles Macintosh, a chemist from Glasgow. He saw the potential: rubber can be dissolved in Coal Tar Naphtha - and this in turn can be applied to cotton fabric. Combined with two layers of fabric, the result was a waterproof material - the basis for the first functional raincoat. Macintosh patented his method in 1823. The price? Today we would call it a designer piece. Which is surprising when you consider the smell. Because it was pungently chemical and tar-like. Not for sensitive noses. Did it detract from its popularity? No, the demand was enormous - especially among the British army. It was the American Charles Goodyear who solved the odour problem: by treating natural rubber with sulphur - known as vulcanization - he made it suitable for everyday use. Elastic, durable, and you could wear it without passers-by changing sides of the street. Today, we tend to think of car tires when we hear the name Goodyear. You can read here in K-Mag why vulcanization was also an accidental find. The German “Friesennerz” originated as protective clothing for fishermen. But people also wanted to stay dry on land when it rained. Copyright: AI-generated From fishing raincoat to invisible membrane Fast forward to the 1970s : the bright yellow, so-called “ Friesennerz ” becomes a cult item in northern Germany. PVC on polyester - practical, robust, highly visible. Not only fishermen wore them, but also city dwellers and children. The problem? After an hour of cycling, you're swimming in your own juice. The simple logic behind it: What doesn't let rain through from the outside doesn't let sweat out from the inside either. The solution came from space travel . Well, almost. In 1969, a chemist named Robert W. Gore (that's right, the guy from Gore-Tex) accidentally developed a material that changed everything: expanded polytetrafluoroethylene (ePTFE). He stretched PTFE so much that a structure with billions of tiny pores was created. The result? A membrane that doesn't let water through, but lets water vapor (i.e. sweat) out. For the first time, it stayed nice and dry under a rain jacket or coat. How a jacket breathes (without lungs) Modern rain jackets are sandwich constructions with several layers: Outer fabric : usually polyamide (nylon) or polyester - robust and lightweight. A DWR (“Durable Water Repellent”) coating sits on top, which allows water to roll off like on a lotus flower. The membrane : the centerpiece. Polyurethane (PU), thermoplastic polyurethane (TPU) or the aforementioned ePFTE with microscopic pores. The choice today is huge. Inner lining : Protects the membrane and transports moisture to the outside. Often made of polyester or nylon, sometimes also cotton. Did you know? A high-quality waterproof Gore-Tex jacket can withstand a water pressure of 28,000 mm water column (this corresponds to the pressure of a 28 m high water column and is a measure of the waterproofness of a material). For comparison: a cloudburst produces about 2,000 mm. You could theoretically stack 14 downpours on top of each other. 15 PET bottles you have drunk “Is it sustainable?” - The question hangs over the entire outdoor industry like a storm cloud. The honest answer: it's getting better, but it remains complicated. The good news: Many manufacturers now use recycled polyester. Your new jacket? It might be made from 15 old water bottles. PFC-free impregnations are on the rise. The old perfluorinated and polyfluorinated chemicals - practically indestructible and bioaccumulative - are slowly disappearing from products. Look out for the label: “ PFOA-free ” or “ PFC-free ” Quality pays off: A good rain jacket lasts 10+ years. This is circular economy in practice. The bad news: Microplastic fibers dissolve during washing. This can amount to hundreds of thousands of particles per wash cycle, which end up in the wastewater. Recycling remains difficult: multi-layer composites can hardly be separated by type. What you can do : Use wash bags against microplastics (filter up to 90% of the fibers), wash less often (airing is often enough), and pay attention to repairability when buying. The rain jacket of the future Work is already underway in laboratories around the world: Self-cleaning surfaces based on beetle armor that repel dirt and water in equal measure Adaptive textiles that self-regulate their breathability depending on temperature and humidity Research is focused on developing membranes from renewable raw materials that offer the same performance as materials already in use. 200 years of research on your skin Next time you cycle to work in the fall rain and arrive dry - think about this for a moment: a piece of scientific history lies on your shoulders. Synthetic products have revolutionized weather protection. Not despite, but because of their unique properties. The challenge for the next 200 years? To combine this functionality with ecological responsibility. FAQ - Questions about rain jackets and synthetics What makes a rain jacket really waterproof? → The combination of membrane (PU/TPU with micropores), DWR coating on the outside and sealed seams. Water column values from 10,000 mm are considered waterproof. Will the coating lose its effect over time? → Yes, the DWR layer wears off. You will notice it when water no longer beads up and the fabric becomes soaked. Solution: Re-impregnate (spray or wash-in). Which plastics are in my rainwear? → Outer: Polyamide (nylon) or polyester. Membrane: polyurethane (PU), TPU or ePTFE. Zippers: often polyoxymethylene (POM). Practically every component is a polymer. Breathable - what does that actually mean? → Measured in MVTR (Moisture Vapor Transmission Rate): How many grams of water vapor per square meter get through in 24 hours. Good jackets manage 10,000+ g/m²/24h. Can I repair a rain jacket instead of throwing it away? → Absolutely! Seal holes with patches, renew waterproofing. Many manufacturers offer repair services. A new jacket usually costs considerably more. How sustainable are plastic rain jackets? → It depends: Recycled material, durability, PFC-free and repairability are plus points. Microplastics and difficult end-of-life recycling remain problems. The best jacket is the one you wear for 10 years. Fancy tinkering with the rain jacket of tomorrow yourself? Textile technology, polymer chemistry, materials science - the plastics industry is looking for creative minds who can combine functionality and sustainability. At the K trade fair , you can find out about training and study opportunities and talk to professionals from the industry. Click here for the Young Talents of the K trade fair! Who knows - maybe you will develop the first completely compostable high-tech membrane. The industry is waiting for you. More exciting reading recommendations in K-Mag: Fluorinated polymers for the circular economy Innovation in collaboration: How a network aims to revitalize the plastics and rubber industry The portrait was generated by AI. Author: 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. This article was created with additional AI tools. At a glance The history of the raincoat is a journey through 200 years of material research: from rubberized fabrics to high-tech textiles with microporous synthetic membranes such as Gore-Tex. Modern rain jackets keep you dry and are breathable. Sustainability is becoming more of a focus - but recycling remains a challenge. More around Plastics in Practice

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  • Plastics in the Packaging Industry: More than just a protective cover

    Part 1 of the series “Focus on User Industries: Packaging” Exclusively for K-Mag Transparent or printed, small or large. There is the right packaging for every product. The variety of options on offer can be experienced again this year at K; Copyright: Messe Düsseldorf/ctillmann 06.08.2025 A cup that keeps yogurt fresh. A blister pack that protects medication. A tray that transports food. Plastic packaging is everywhere. And the choice of material determines durability, recyclability, and carbon footprint. While a PET yogurt cup guarantees freshness for weeks and is significantly lighter than glass, hygienic polypropylene in blister packs ensures sterile storage of medicines. Modern monomaterial packaging is much easier to recycle than composite materials, which often end up in residual waste. The carbon footprint of plastic packaging is often lower than that of alternative materials during transport due to its lower weight. This is clearly illustrated by rPET wine bottles, as explained in this interview with ALPLA ! But what exactly is “typical packaging,” and what criteria must manufacturers consider when selecting it? The answer lies in a complex interplay of material properties, application requirements, and sustainability goals—from the barrier function against oxygen to recyclability in the circular economy system. This means that there is no such thing as a one-size-fits-all packaging solution. It always depends on the specific product that needs to be packaged. Diverse applications of plastic packaging The packaging for products can be selected and designed as required; Copyright: Messe Düsseldorf/ctillmann Food packaging for greater hygiene and safety Plastics are indispensable in the food packaging industry. For example, PET dominates beverage bottles due to its barrier effect against CO₂, while polypropylene (PP) dominates yogurt cups due to its heat resistance up to 130°C, which is particularly hygienic when in contact with food. Polyethylene (PE) is used as LDPE for flexible cling film and as HDPE for sturdy milk bottles. Composite materials with barrier layers are used for more demanding applications. Packaging is essential for keeping medicines sterile. Medical packaging for greater patient safety Sterile and secure packaging is essential in the medical sector. PVC dominates blister packaging—it offers transparency for visual inspection if desired, and its low water vapor permeability protects medications from moisture. PE and PP withstand sterilization processes without damage, while cyclo-olefin copolymers (COC) offer glass-like transparency in injection vials with pharmaceutical purity. There are a multitude of design options for cosmetics packaging; Copyright: Messe Düsseldorf/ctillmann Consumer goods packaging for appealing products Plastic packaging offers numerous design options in the consumer goods sector. ABS enables high-quality visual appearances for cosmetics packaging with excellent surface quality, while PETG scores points in display packaging with its crystal-clear transparency. Boomerang packaging can be returned to the company via the mailbox; Copyright: boomerang Transport packaging to protect goods Robust yet lightweight packaging materials are required for the safe transport of goods. Various plastic solutions are used for this purpose: shrink and stretch films effectively secure pallet loads, while bubble wrap provides optimum protection for goods that are sensitive to impact. Expanded polystyrene, better known as Styrofoam, serves as reliable protective packaging due to its excellent cushioning properties. Plastic crates and containers have established themselves for reusable applications, impressing with their durability and stability while also protecting the environment through repeated use. Boomerang is a start-up that has impressed with an exciting idea for mail order. Its solution focuses on shipping bags made from recycled plastic as a sustainable alternative to disposable shipping bags. The bags help to reduce packaging waste by being reusable up to 50 times. They are made from 100% recycled polypropylene, are resealable, and can be stored and transported in a space-saving manner. Customers who order via the system can simply fold the shipping bag after delivery and return it to the company by mail. There, the bags are cleaned and returned to the cycle. A similar reusable system for parcel logistics has also been developed by BOOXit. Exciting insights into this system can be found in this K-Mag interview ! The most common plastics Polyethylene (PE): For films, bags, and bottles. Flexible, chemical-resistant, easy to weld. Polypropylene (PP): Stable, heat-resistant, and therefore ideal for cups, for example. Polyethylene terephthalate (PET): Resistant to many chemicals, therefore often used in food packaging such as bottles and trays. Polystyrene (PS): Known to many as Styrofoam. Lightweight and insulating, used for example in thermal packaging. Lighter and more resource-efficient Compared to other packaging materials such as glass or metal, plastics are significantly lighter. This leads to considerable savings in transport costs and is beneficial for climate protection: Lower fuel consumption and CO₂ emissions during transport Higher transport capacity per vehicle Less material consumption with the same protective function Recyclable packaging concepts Design for recycling is becoming increasingly important in packaging development. Solutions such as monomaterials are preferred over composites that are difficult to separate, and the use of recycled materials in new packaging is on the rise. In addition, color coding facilitates sorting in the recycling process, while problematic additives are reduced to improve reusability. Read our article on “Design4Recycling for yogurt cups” Recyclates have great potential When it comes to a closed material cycle, there is no getting around recyclates . Mechanical recycling is now well established, while chemical recycling is still in development. So, the approaches are there, but manufacturers are currently still faced with a price issue. New materials are often still cheaper than recyclates. Material savings through intelligent design Innovative designs and a sophisticated approach to material design significantly minimize the use of materials in modern packaging solutions. This not only leads to cost savings, but also contributes significantly to the conservation of resources: Thin-walled packaging with optimized stability thanks to special reinforcement ribs and strategically positioned stiffening elements that maintain mechanical strength despite reduced material usage Corrugated profile structures for greater rigidity with lower raw material consumption, transferring the biomechanical principle of natural structures such as corrugated cardboard to plastics Concentrates and multi-packs and refill packs with reduced packaging volume, which can reduce the material requirements for primary packaging by up to 80% while increasing transport efficiency Bioplastics in comparison: opportunities and limitations There are high hopes that bio-based materials will be able to replace fossil raw materials. These materials are based on sugar cane, corn, or cellulose, for example. Unfortunately, however, bio-based does not automatically mean environmentally friendly. Even bioplastics are not always biodegradable. Furthermore, they often end up in the same waste stream as conventional plastics. This means that their true potential is unfortunately wasted. However, the industry is continuing to work on finding solutions. Further information on bio-based plastics in food packaging can be found here! For anyone working on material innovation and future trends, packaging remains an exciting—and challenging—topic. Some of these new developments can be experienced at K 2025. What new applications will there be? If you don't want to wait until K 2025 in October, we will soon be presenting specific solutions from exhibitors in part 2 of our series “Focus on user industries: Packaging.” The portrait was generated by AI. Author: 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 Plastic packaging ensures freshness, hygiene, and product protection. Its low weight saves CO₂ during transport, while trends such as monomaterials, the use of recycled materials, and intelligent design improve recyclability and resource efficiency. Bio-based plastics are also becoming more prominent. More around Plastics in Practice

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  • Electronics meets Production: Focus on Plastic Solutions and Systems

    Part 2 of the series 'Focus on User Industries: Electronics' Exclusively for K-Mag This scanner housing was made of yellow and black plastic and presented at K 2022; Messe Düsseldorf/Constanze Tillmann 24.09.2025 Plastics are indispensable in the electronics industry – as Part 1 of our series has already shown. Whether housings, insulators, or conductive components – modern plastics make many applications possible in the first place. But it's not just the materials that count, it's also their precise processing. In the second part of the series, we show how plastics technologies are shaping the production of electronic components – from material selection to machine solutions. And, of course, we highlight the role of K 2025 as a showcase for these developments. In modern controllers, not only is the casing made of plastic, but flexible plastic substrates are also used inside, for example for pressure-sensitive sensor films. A prime example of printed electronics that combines design and function; Copyright: Messe Düsseldorf/Constanze Tillmann Production requirements – Precise, integrated, smart Depending on requirements—from quantity to geometry—different processing techniques are used. Injection molding enables the efficient mass production of precise components, while 3D printing offers high flexibility for customized designs. Processes such as thermoforming or roll-to-roll printing (R2R) are used for films and special applications. The electronics industry demands plastics with special properties: electrical insulation or conductivity, flame resistance, mechanical strength, UV and chemical resistance, and sustainability through recyclability . Color, feel, and durability also play a role, especially for micro and precision parts, such as those used in game controllers. Event tip at K 2025! Moldsonics in Hall 6: Real-time monitoring for sustainable production: As a finalist in PlasticsEurope's TOWARDS ZERO Startup Battle, Moldsonics will be demonstrating on October 13, 2025 (Hall 6, Booth C40) how its inline sensor technology reduces waste in injection molding and enables data-driven decisions in real time—for greater sustainability in plastics processing. Moldsonics GmbH Manufacturing modern smartphones: Equipment runs 24/7: Robots handle removal and assembly, while intelligent systems automatically adjust tools. Automation and digitalization as key drivers Modern electronics production would be unthinkable today without automation and digitalization. Devices manufactured in their millions, such as smartphones, require maximum precision, fast cycle times, and consistent quality. These are requirements that only automated processes can meet. Digitalization is revolutionizing processes The digital transformation has fundamentally changed plastics processing. Inline quality control is particularly valuable: high-resolution camera systems and measurement technology check every part produced in real time. Defective components are automatically sorted out before they even leave the production line. These systems can detect surface defects in the micrometer range, ensuring consistently high product quality. Industry 4.0 in practice Digital twins now make it possible to simulate and optimize complex injection molding processes before actual production begins. Parameters can be tested and adjusted virtually before the first mold is built. In ongoing production, AI-supported systems ensure continuous process optimization, with parameters being adjusted in real time to achieve the best possible quality. Example ENGEL at K 2025 An example of printed electronics: Copyright: Covestro Printed electronics – design freedom meets functionality Printed electronics are fundamentally changing the manufacture of electronic circuits. Conductive inks are printed directly onto plastic substrates such as PET or polyamide – similar to inkjet printing. This creates ultra-thin, flexible circuits that can be bent or stretched. The advantages: lower costs, fewer chemicals, new application possibilities, e.g., in smart packaging, medical wearables, or smart textiles. K exhibitor Covestro has already presented an example of the application in wearables at MEDICA . The Colibri demonstrator from Covestro and Cicor also shows how electronics can be integrated directly into plastic surfaces – with translucent Makrolon® and finely printed conductor tracks using aerosol jet printing. The resulting surfaces are decorative, functional, and recyclable. This is a strong impetus for sustainable product design and future-proof technologies, as this quote from Karl-Heinz Fritz, Vice President of Development & Technology at the Cicor Group, clearly illustrates: “Printed electronics will be utilized in many new application areas. The use of printing technologies will help to make manufacturing processes more efficient and miniaturize electronic systems. Covestro offers in its product portfolio polycarbonate grades whose properties make them ideally suited for printing with the aerosol jet printing process used by Cicor.” The quote was taken from the news page on this topic under Covestro Solutions, which you can find here . Recycling-friendly inks for tomorrow's electronics The INM – Leibniz Institute for New Materials – develops functional inks based on tailor-made plastics that are specially optimized for use in printed electronics. Polyurethanes and other polymeric binders provide properties such as elasticity, flexibility, and adaptability to mechanical stress. Combining these with conductive fillers creates inks that are both elastic and electrically conductive. This makes it possible to create heating systems or sensors, for example, that work reliably even under severe deformation. A particular focus is also on the development of sustainable polymer formulations that facilitate recycling processes and thus enable more environmentally friendly use of printed electronics. Review: Solar laptop bag A visionary application of printed electronics was presented at K 2010 in the form of a solar laptop bag: thin, flexible, and lightweight, it enabled mobile devices to be charged using integrated plastic solar cells. The bag symbolizes the potential of polymer-based electronics—functional, cost-effective, and ready to print. An idea that was ahead of its time and shows how early plastic innovations paved the way for “electronics everywhere.” K 2025 trade fair: Platform for solutions from granulate to finished component Whether it's sensor technology, energy storage, or smart surfaces, plastics are driving the development of electronics. K 2025 showcases innovations along the entire value chain: from high-performance polymers and machine solutions to networked systems for electronics production. An overview of exhibitors specializing in plastic components and systems for electronics production can be found here in the exhibitor database . You can find all events during K 2025 in our event search! The portrait was generated by AI. Author: 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 Plastics are key components in electronics production. Modern processing technologies such as injection molding, 3D printing, and printed electronics enable high-performance, lightweight, and sustainable solutions. Digital twins and AI drive efficiency and quality. At K 2025, the industry will showcase how materials, machines, and applications come together in practice. Exhibitors of important production technologies can be found here: Injection molding : This process is suitable for the mass production of complex plastic parts in large quantities and is cost-effective for large volumes. 3D printing /additive manufacturing: Enables the production of highly customized housings and prototypes as well as complex designs that are difficult to implement using other processes. CNC machining is often used for precise housing parts and functional elements of electronic devices. More around Plastics in Practice

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  • Plastics as Drivers of the Mobility Revolution – Exhibitors at K 2025 Demonstrate This

    Part 2 of the series 'Focus on User Industries: Automotive' Exclusively for K-Mag K 2025 brings exhibitors and trade visitors together to present the latest plastics solutions for the automotive industry. Copyright: Messe Düsseldorf 03.09.2025 From lightweight construction and electromobility to closed material cycles – K 2025 will show how the plastics industry is supporting the transformation of the automotive industry in many different ways. Exhibitors from all areas of the value chain will present innovations that make mobility lighter, more efficient and more sustainable. This part 2 of our article series highlights how exhibitors at K 2025 are picking up on these developments and taking them further. In part 1, you read where and how plastics are used in cars – and what they do there. The Efficient Alternative: Lightweight Construction with Plastics in Vehicle Manufacturing Less weight means less energy consumption – a rule of thumb that applies more than ever in the automotive industry. Modern fibre-reinforced plastics are increasingly replacing aluminium or steel components today, offering additional advantages. ENGEL's clearmelt process creates scratch-resistant, high-quality surfaces directly in the injection moulding process. Copyright: ENGEL ENGEL focuses on hybrid solutions and lightweight components that can replace metal components. 'Our focus is on material substitution with lightweight components made of fibre-reinforced plastics that can replace aluminium components,' says Dr Gerhard Dimmler, CTO at ENGEL. The clearmelt process also enables components to be coated with polyurethane directly in the injection moulding process – an alternative to painted sheet metal parts that improves surface quality and scratch resistance. SABIC is also demonstrating with its new MEGAMOLDING™ platform that large-format thermoplastic parts can be an economical alternative to metal and thermosets. Whether battery housings, truck components or structural parts – the process saves weight, simplifies production and opens up new design freedoms. Plastics for E-Mobility – Safe Materials for High Voltage and Batteries ALBIS supplies materials for wallboxes that combine flame resistance, UV resistance and a long service life. Copyright: ALBIS With the boom in electric mobility, the demands on materials and components in vehicles are increasing. Components must be electrically safe, flame-retardant, durable and often particularly compact. ALBIS addresses these requirements with materials that achieve a creepage current resistance of up to 600 V. 'For such applications, we offer material solutions with a creepage current resistance (CTI) of up to 600 V, among other things,' explains CEO Horst Klink. At K 2025, the company will be showcasing wall boxes that combine flame resistance, weather resistance and light diffusion, among other things. With its 'bumper to bumper' approach, Envalior takes a holistic view of the powertrain. 'Engineering materials have the potential to be an important enabler for the next phase of electric mobility,' says Tim Arping. At the trade fair, the company will be presenting Pocan® PBT for high-voltage connectors – with 600V CTI, halogen-free flame retardancy and high hydrolysis resistance. SABIC's MEGAMOLDING platform enables lightweight, large-format thermoplastic parts such as battery housings for electric vehicles. Copyright: SABIC Function Integration and Design Freedom Thanks to Plastic Components The fewer components, the more efficient the production. Function integration is therefore a key factor in modern vehicle construction. Plastic solutions can combine several tasks in one component – from mechanical stability and heat dissipation to protective functions. 'An important trend is functional integration, in which plastic components perform multiple tasks, thereby improving efficiency in the installation space,' says Dimmler. SABIC is also adopting this approach: MEGAMOLDING enables the consolidation of components, facilitates assembly and paves the way for easier disassembly and recyclability. Recycling and Circular Economy – Sustainable Plastics for the Automotive Industry MOCOM produces high-quality recycled compounds that are competitive with virgin materials. Copyright: MOCOM The new EU End-of-Life Vehicles Directive sets ambitious targets for the use of recycled materials and the recyclability of vehicle components. Many exhibitors are responding to this with material innovations and closed-loop systems. MOCOM is presenting several examples at the trade fair, including PIR PC/PET compounds and polypropylene with recycled carbon fibre. 'As the market leader in high-quality recycled compounds that are competitive with virgin materials, we believe we are already well positioned in this area,' says Kurt Maschke, Senior Director Global Business Development Automotive at MOCOM. ALBIS is also pursuing this path with a broad portfolio of PCR and PIR materials, chemically recycled polymers and biopolymers. Which of these will meet the ELV requirements in the future will be decided in the coming years. Outlook for K 2025: Trends and Innovations for Vehicle Construction Exhibitors agree that electrification, sustainability and new mobility concepts will also be the major topics in Düsseldorf. ENGEL expects ‘valuable impetus for new partnerships and joint developments along the automotive value chain.’ SABIC sees the trade fair as an opportunity to show how new materials enable 'sustainable mobility, especially in the field of electric vehicles, and circular design'. And MOCOM wants to demonstrate at its stand 'how modern plastic solutions make mobility more sustainable, lighter and safer'. In Part 1, we showed where plastics are used in vehicle construction, what functions they perform and what trends are driving the industry. If you missed this overview, you can read the article here! One thing is clear: K 2025 will not only showcase the latest technologies – it will also make it clear that the mobility transition would be unthinkable without plastics. The Exhibitors at a Glance ENGEL – Hall 15 / B42 & C58 Core competence: Injection moulding technologies for lightweight construction and functional integration K 2025 Highlight: Clearmelt process for scratch-resistant, high-quality surfaces directly in injection moulding; lightweight components made of fibre-reinforced plastic as a substitute for metal To the exhibitor profile ALBIS – Hall 6 / A62 Core competence: Engineering plastics for e-mobility, charging infrastructure and high-voltage components K 2025 highlight: Material solutions with up to 600 V CTI for wall boxes, battery housings and high-voltage connectors; use of PCR/PIR materials and biopolymers To the exhibitor profile Envalior – Hall 6 / B11 Core competence: Specialised materials for the entire automotive powertrain K 2025 highlight: Pocan® PBT for high-voltage connectors with 600 V CTI, halogen-free flame retardancy and hydrolysis resistance; laser-transparent materials for sensor systems To the exhibitor profile SABIC – Hall 6 / D42 Core competence: High-performance thermoplastics for large-format and structural vehicle components K 2025 highlight: MEGAMOLDING™ platform for battery housings, truck components and other structural parts; enables component consolidation and simplified recycling To the exhibitor profile MOCOM – Hall 6 / A62 Core competence: Recycled compounds and tailor-made solutions for e-mobility and lightweight construction K 2025 highlight: Centre console with 30% weight reduction and front grille made of PIR PC/PET using a closed-loop process To the exhibitor profile 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 Exhibitors at K 2025 will show how plastics are driving the mobility revolution – with solutions for lightweight construction, e-mobility, functional integration and recycling. More around Plastics in Practice

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  • Towards new Packaging Solutions: Protective Material made from starch as a Sustainable Alternative

    Exclusively for K-Mag The sustainable protective packaging can be customized to fit the products perfectly; Copyright: Storopack 12.11.2025 Whether electronics, ceramics, or glass—sensitive products need reliable protection during shipping. This can be achieved with traditional materials such as bubble wrap or PE foam. But are they sustainable for the future? With RENATURE® Wrap, Storopack has developed an environmentally friendly, home-compostable alternative made from plant starch. In an interview with K-Mag, Steffen Armbruster , Business Unit Manager at Storopack, explains how the new protective packaging works, what role yellow peas play, and why clear legal regulations for compostable packaging are urgently needed. Steffen Armbruster, Business Unit Manager bei Storopack; Copyright: Storopack Alternative to bubble wrap: The idea behind RENATURE® Wrap What was the motivation behind the development of RENATURE® Wrap—and how does it differ specifically from conventional bubble wrap or PE roll foam? Steffen Armbruster: RENATURE® Wrap is a basic component of our new RENATURE® product family. This includes 3D packaging (RENATURE® 3D), insulated packaging (RENATURE® Thermo), and RENATURE® Wrap for wrapping and covering fragile goods for safe shipping. We wanted to develop an innovative and sustainable alternative to existing products on the market in order to offer our customers better solutions for sustainable protective packaging. RENATURE® Wrap is easy to use because it is very flexible and, thanks to its strength, can be easily joined together without adhesive and shaped into the desired form by lightly spraying it with water. Compared to bubble wrap or PE foam rolls, the biggest difference is certainly its certified home compostability and the fact that it can be reused many times as packaging. Did you know? The plant-based ingredient in RENATURE® Wrap comes from yellow peas: they are used as a crop rotation plant in sustainable agriculture. They bind atmospheric nitrogen in the soil, which eliminates the need for mineral fertilizers and improves fertility for subsequent crops. The material is versatile, reusable, and compostable; Copyright: Storopack Yellow peas as a raw material: sustainable and bio-based What was the deciding factor in choosing this raw material, and how do you assess its environmental impact? Armbruster: We were looking for a raw material that was bio-based, resource-efficient, compostable, and at the same time did not compete with food. We came across a plant starch that is obtained from the residues of protein extraction from yellow peas. Yellow peas require little fertilizer and water to grow and are often used in sustainable agriculture to break up crop rotation. They improve soil fertility and help reduce diseases and pests. So it's a real win-win situation: the ideal raw material for sustainable packaging. How do you ensure that RENATURE® Wrap is disposed of correctly in practice? Armbruster: Bio-based, compostable packaging is only truly sustainable if its disposal process also works. We therefore rely on a multi-stage approach: the most sustainable option is to reuse the packaging, which is perfectly possible with RENATURE® Wrap as it is very flexible and can be quickly and individually adapted to the goods to be protected. The next step is clear communication for the end consumer, for example in the form of QR codes, which we use to point out the locally permitted disposal options and also provide information about the TÜV Austria home composting certificate. To make RENATURE® Wrap even more sustainable, uniform regulations for the approval of compostable packaging in organic waste bins, which unfortunately currently vary depending on the EU country and even at the municipal level, would provide even more clarity. Click here for the interview with Mara Hancker on the topic of “Packaging law and Recyclability.” You can also find exciting information on the topic of packaging at interpack! Copyright: Storopack Advantages in everyday use: Flexible material for customized packaging solutions What feedback have you received regarding the handling of the material in the packaging process? Armbruster: Our customers to date are very satisfied and we are receiving very positive feedback. Above all, the ease of handling, high flexibility, and fast adhesion are enormous advantages, as they allow three-dimensional shapes to be created in small quantities and with little effort. This enables our customers to respond quickly to their respective packaging requirements with just one packaging material. Bio-based materials are considered a great hope for the packaging industry. Where do you currently see the greatest potential—and also the biggest misconceptions? Armbruster: Unfortunately, packaging often has negative connotations in the public perception. Yet it serves an important function: protecting products, because only a product that arrives safely can be enjoyed and conserves resources. If this packaging is now made from bio-based materials, that is a big step toward greater sustainability in the packaging industry. Many companies are faced with the dilemma of balancing economic efficiency and sustainability. How do you achieve this—and where would you like to see stronger political or market-driven impetus? Armbruster: At Storopack, as a family-run, medium-sized company, sustainability is part of our corporate DNA. It is true that sustainable solutions are often more cost-intensive, but there is definitely a rapidly growing market for them, as end customers expect these sustainable solutions. We meet this requirement with our new RENATURE® products and are well positioned to serve this market segment. Furthermore, sustainability is a central component of our corporate strategy, enabling us to develop long-term, innovative solutions such as RENATURE®. However, we also need planning and legal certainty from politicians. The first step in this direction was taken at the beginning of this year with the adoption of the PPWR. Read more about a start-up's sustainable stretch film in this interview! From Bioplastics to Reusable Packaging: Part 2 of the series “Focus on User Industries: Packaging” 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 With RENATURE® Wrap, Storopack has developed environmentally friendly protective packaging based on plant starch that is home compostable, flexible in use, and reusable. In this interview, Steffen Armbruster talks about the advantages over conventional bubble wrap, the importance of bio-based materials, and the political framework conditions necessary for greater sustainability. More around Plastics in Practice

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  • Sustainable plastics for food packaging

    Consumers' growing environmental consciousness leads to added pressure on the packaging industry to develop sustainable solutions. Copyright: iStock 22.11.2024 The plastic films used in the food industry continue to predominantly be made of conventional plastics such as polyethylene (PE) and polypropylene (PP). In 2022, packaging accounted for around 40 percent of total plastic consumption worldwide, with food packaging making up a significant share. One small bright spot is that in Europe, there is a growing trend towards using sustainable materials. One of the global players in the development of innovative materials is Taghleef Industries, an interpack exhibitor and member of the SAVE FOOD initiative. The Dubai-headquartered company operates globally and specialises in the production of PP-based, bio-based and bio-degradable films for flexible packaging, labels, graphical applications, decorative surfaces and industrial applications. Allegra Muscatello, product manager at Taghleef Industries, describes the complexities of working with innovative packaging solutions: "When we talk about sustainable packaging, it's a broad concept that can include different types of films – not only those that are bio-based or bio-degradable. Even conventional fossil-based plastics can be sustainable if they are designed for recyclability or produced using recycled raw materials." High demands on plastic for food packaging In the food sector in particular, the challenges around packaging are enormous. In this area, innovative plastic or bio-based materials must offer the same reliability as conventional materials. To give just a few examples, grated cheese needs reliable, airtight packaging to protect the cheese from moisture and oxygen and prevent mould from forming. Coffee capsules have to be extremely tightly sealed to preserve the flavour and freshness of the coffee. This creates strict requirements with regard to barrier properties, enabling the packaging to be protected from oxygen, moisture and light. At the same time, the packaging must be heat-resistant to withstand the high temperatures while the coffee is being made in a pod machine. Bio-based punnets for berries and grapes need to be highly sturdy to support the weight of the fruit and absorb impact during transport. At the same time, they must be breathable to prevent mould from forming while still preventing the fruit from drying out. In addition, these packaging solutions need to be transparent so that consumers can see the quality of the fruit on the shop shelf, which can be a challenge with bio-based plastics. Yoghurt pots made of bio-based plastic require tightly sealed barriers to protect the yoghurt inside from oxygen and light and preserve its freshness. In addition, they must be stackable and stable without deforming, while also being easy to recycle or compostable. Another problem revolves around the packaging's suitability for different temperatures, as yoghurt is often stored in refrigerated units. By contrast, other foods such as salad or fruit need breathable packaging so that the food does not spoil. Taghleef Industries has solutions ready for a whole host of different applications. "Food packaging in particular always depends on good barrier properties to keep products fresh and extend their shelf life", emphasises Muscatello. "We already have PP-based films with strong barrier properties in our product range. We are continuing to work on further optimising our NATIVIA® bio-based and bio-degradable films using coating and metallisation." Bio-based and biodegradable films on the rise PP-based, bio-based and bio-degradable films for flexible packaging solutions differ from conventional plastic materials primarily in their composition and eco-friendliness. PP-based films (polypropylene) are made from fossil raw materials. Bio-based films are made from renewable raw materials such as cornstarch. PHAs are a group of bio-degradable polyester materials produced by micro-organisms to store energy and carbon. The abbreviation PBSA refers to a bio-degradable polyester. It is commonly used in bio-degradable packaging materials and films due to its high degree of mechanical strength and flexibility. Bio-degradable films are often made from bio-based or fossil resources and break down into natural components under certain conditions (e.g. when composted). They offer a green alternative to conventional plastics but are often less durable. "Our company makes polylactide PLA films that are bio-based and industrially compostable. In addition to PLA, we are now also certifying new bio-polymers such as PHA and PBSA to improve the films' bio-degradability and achieve a home compostability certification", says the product manager. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Annual growth expected for sustainable plastics Worldwide, the consumption of bio-based and bio-degradable packaging is expected to increase by around 15 percent annually over the next few years (sources: Statista, Plastics Europe). Europe is currently leading the shift towards bio-based packaging materials, while the United States still relies more heavily on conventional plastics. "The development of new materials is driven by a growing awareness of environmental issues and the need for more sustainable solutions", explains the packaging expert. "More and more consumers are placing a growing emphasis on sustainability, and this is increasing the pressure on businesses. There is a strong demand for bio-degradable and compostable packaging, especially in the food sector." Alternative materials are still more expensive than conventional ones – but for reasons of competition, social responsibility and long-term potential cost savings, there is no other way forward. EU regulations as a driving force for sustainable packaging In addition to this, EU legislation governing sustainable packaging is growing stricter, especially for food. New regulations are being introduced with a view to promoting the transition to a circular economy and reducing environmental impact. One of the requirements in the Packaging and Packaging Waste Regulation (PPWR) is a set level of recycled content for certain packaging solutions by 2030. This means that a defined percentage of the material must be sourced from recycled material. Reusability of packaging and minimisation of material thickness to avoid unnecessary packaging are two more key concepts in this context. Since 2021, there has also been the Single-Use Plastics Directive (SUPD), which aims to reduce the amount of plastic packaging that is only used once. The EU, then, is pursuing ambitious goals to make packaging more sustainable under its European Green Deal and Circular Economy Action Plan. In addition, the bloc's EPR rules ensure extended producer responsibility. These specify that the organisation placing packaging on the market must be responsible for managing and recycling it. "Businesses that make an early switch to sustainable packaging solutions should generally be better prepared for future regulatory changes", says the product manager. "As a result, it is well worth it for organisations to gear themselves up for the future in good time." Redesign of packaging - service for innovations Arriving at new solutions requires support and expertise. "At Taghleef Industries, we offer comprehensive services under our Redesign label. When we provide these services, we develop a bespoke solution for customers to switch from a traditional packaging structure to a more sustainable and innovative alternative", says Muscatello. "In doing so, we keep an eye on their specific requirements for product protection and product performance, combining these with the sustainability requirements at hand." Taghleef Industries also collaborates with suppliers of printing inks, adhesives and coatings to review their compatibility with newly developed films. Networking with global partners Participation in the SAVE FOOD project plays an important role in fostering collaboration with strong partners. "As an international producer of sustainable packaging materials in the food sector, we recognise that we have a role to play in actively combatting food waste", explains the committed plastics expert. "The SAVE FOOD platform offers us the opportunity to work with global partners to devise innovative solutions that improve food protection while also conserving resources and minimising environmental impact. Working together with other organisations committed to this goal around the world enables us to create a more sustainable future and conserve valuable resources together." Source interpack SPOTLIGHT More around Packaging

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  • Health Meets Resource Conservation: Making Blister Packaging More Sustainable

    Young scientist Olivia Falconnier Williams shows how valuable raw materials can be used responsibly Exclusively for K-Mag Olivia Falconnier Williams is a young scientist and shows how blister packaging can be made more sustainable in order to conserve resources in the healthcare sector. 21.08.2024 During the last allergy season, they may have ended up in your garbage once again: Blister packs. And you may have noticed how few tablets there are in a comparatively large pack. Not particularly sustainable, is it? Olivia Falconnier-Williams thought so too, and together with Prof. Dr. med. Walter E. Haefeli from Heidelberg University Hospital, she researched how packaging could be made more resource-efficient. Olivia Falconnier Williams is a young scientist and the daughter of a pharmacist in Switzerland. Copyright: private In an interview with K-Mag, Olivia Falconnier Williams talks about her research findings on more sustainable blister packaging and her experiences as a young scientist - and gives tips to other young researchers. What prompted your research on the topic of waste prevention in blister packaging? Olivia Falconnier Williams: Now that the healthcare system has become one of the largest consumers of resources in Western countries, responsible management of these resources is becoming increasingly important. Awareness of this connection is only just emerging in the healthcare sector and general standards for sensible resource conservation have neither been discussed nor introduced. This makes it all the more important to identify options that conserve resources and can be implemented immediately without any loss of quality or regulatory obstacles. What conclusions have you drawn from your research? Falconnier Williams: In a very large sample of medicines that are very frequently taken in Germany, we showed that they are predominantly packaged in individual blisters, but practically never in a resource-saving manner. For example, the packaging material of the blister strips between the blister chambers typically took up much more space (= material requirement) than the actual blister chambers. The extrapolation of an optimal placement with little space in between showed that typically one third of the packaging material - plastic-aluminum composite material, rarely mainly aluminum - could be saved. For many reasons, this practice should be changed as soon as possible: it is not necessary to leave such large gaps for the correct removal of medicines. The material used is practically never recycled, as it is difficult to separate the glued or welded (composite) materials again in a meaningful and economical way. The secondary packaging that wraps the blister strips is also correspondingly larger, which is why the avoidable weight of the primary packaging is automatically added to the avoidable weight of the secondary packaging; both lead to larger transport volumes and weights and ultimately to higher transport costs per dosage form. Given the sheer volume of medicines consumed in Germany (and worldwide) and the extremely long transport routes (due to production often on other continents), it is astonishing why this has not been optimized long ago. Blister packaging causes more waste than necessary. What steps could be taken to put your findings and proposed solutions into practice? Falconnier Williams: There are already packs on the market that package the dosage forms very compactly, and there are no objective, medical or regulatory reasons not to declare this a new standard. Such an implementation could also be promoted by market-based incentives using already established methods (e.g. by exempting patients from co-payment, by preferential inclusion in the discount agreements between health insurance funds and manufacturers or by prioritization in the selection of hospitals' product ranges by their local drug commissions). In addition, the labelling of resource-optimized pharmaceutical packaging could create transparency for customers as to whether the manufacturer has made efforts to optimize the ecological footprint. Especially when choosing generics, patients can directly determine which product they would like and thus actively limit the sale of non-ecological products. In a similar way, pharmacies could also adjust their stock range accordingly. Both manufacturers and pharmacies could advertise the fact that they also take care of these issues. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Your project idea came about while you were preparing for your graduation. How did you manage to start your research at such an early stage of your academic career and what challenges might you have overcome? Falconnier Williams: The idea for the project came about while I was preparing for my Matura (Swiss general qualification for university entrance), in the context of the Matura thesis, my final scientific project. I am convinced that if you really want to do something, there is never a bad time. It was a unique opportunity for me to work so closely with Prof. Dr. med. Walter E. Haefeli from Heidelberg University Hospital - so I didn't even ask myself whether it might still be a bit early in my academic career. It was therefore obvious that some of my first scientific work was challenging. I had to learn how to collect and analyze data, how to research and cite correctly, how to structure a paper and much more. "Every wish, every flash of inspiration and every experiment has a valuable influence on the end product and is therefore worth paying attention to," Olivia Falconnier Williams encourages young researchers. What message would you like to pass on to other young scientists? Falconnier Williams: I would give them two things: One, working with Prof. Dr. med. Walter E. Haefeli has shown me that no idea is 100% unrealizable. Every wish, every flash of inspiration and every experiment has a valuable influence on the end product and is therefore worth paying attention to. On the other hand, it was also a very instructive time for me on a personal level, because I was under a lot of stress, as I had to juggle my A-level preparations and my involvement in competitive sport alongside this scientific work. This busy weekly schedule required well thought-out planning, which in the end significantly increased efficiency in all three areas. I would therefore recommend anyone in a similar situation to invest sufficient energy in planning and organization. More on the topic of Young Talents: Oliver Fuss talks about how exciting and diverse the plastics industry is. Find out more in the interview with the all-round talent! Yannik Herzog is an electronics technician for automation technology. He explains exactly what he does in this interview. For a career start in the plastics industry, we recommend our comprehensive article! Elena Blume (Editorial team K-Mag) More around Packaging

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  • ESMA Academy: Inkjet know-how for the plastics industry

    Understanding and using new possibilities for digital printing on plastics Exclusively for K-Mag At the ESMA Academy, experts acquire practical know-how about inkjet printing, from ink chemistry to surface preparation. Copyright: ESMA 12.02.2025 The digital printing of plastics opens up numerous possibilities for individualization, efficiency and sustainability. But what technical requirements need to be met? Which materials are particularly suitable? And how can companies make the most of the potential of inkjet technology? Answers to these questions are provided by the ESMA Academy, a training platform for professionals involved in industrial printing processes. In an interview with K-Mag, Oliver Kammann from K-Flow Consulting GmbH talks about the content of the Academy, who it is suitable for and why in-depth knowledge of printing technologies is becoming increasingly important in the plastics industry. Efficient, Flexible, Versatile: Inkjet Printing for Plastics Oliver Kammann, K-Flow Consulting GmbH. Copyright: private What are the advantages of inkjet technology compared to traditional decoration processes, especially for plastics? Oliver Kammann: Inkjet technology offers several advantages. It is a contactless printing process, allowing for variable data and different images on each pass. All colors are printed in a single step without re-registering, improving efficiency. The use of UV LED inks ensures fast and economical curing, with other options like e-beam available. Inkjet also eliminates the need for labels, screens, and printing cylinders, reducing stock requirements. It supports flexible and rigid plastics, including post-forming applications, and enables embossing, frosting, and other effects. Additionally, it is cost-effective for both short and large production runs. Which types of plastic substrates are particularly suitable for inkjet decoration and why? Kammann: The suitability of plastic substrates for inkjet decoration depends on proper surface preparation to ensure optimal ink adherence and image quality. The surface must be in good condition to create a strong bond and minimize ink spread. Some inks are specifically formulated for certain plastics to enhance adhesion. Generally, PET, ABS, PP, HDPE, and PE provide the easiest results. PVC and acrylic can also be used but may require more careful testing to achieve the best outcome. Proper pre-treatment is key to ensuring high-quality prints on any plastic substrate. What opportunities does inkjet offer for product personalization and differentiation? Kammann: With inkjet each image can be unique, whether entirely or in specific parts. It enables variable data and image printing, serialization, and customization with ease. Inkjet allows for the application of embossing, structural effects, and matte or glossy lacquers, adding depth and texture to designs. It also supports security printing and product tracing through special inks or hidden codes created by adjusting drop placement. Barcodes and other tracking codes can be printed on demand, enhancing functionality and security. Learning From the Experts: The ESMA Academy Training Program Inkjet technology enables the flexible and efficient printing of plastic surfaces – ideal for individual designs and sustainable production processes. Copyright: ESMA What specific topics and skills are taught at the ESMA Academy? Kammann: The ESMA Academy is designed for professionals with a basic understanding of inkjet technology, offering in-depth training tailored to specific applications such as plastics, glass, textiles, and functional printing. Each course combines theoretical lessons with practical sessions, covering both general principles and application-specific content. Key topics include ink chemistry, printhead physics, surface pre-treatment, adhesion, and color management. Participants also learn about print defects, ink characterization, waveform optimization, and drying techniques such as UV, IR, and eBeam. Additionally, the program explores ink formulation, filtration, supply systems, and emerging market trends. A strong focus is placed on problem-solving, allowing attendees to engage in open discussions and hands-on fine-tuning of their printing systems. Who is the Academy aimed at and what prior knowledge should participants have? Kammann: Our course is designed for a broad audience, including companies developing inkjet systems, print service providers integrating inkjet into their operations, and end-users or brand owners seeking a deeper technical understanding beyond supplier marketing. Brands, in particular, benefit from learning how to maximize inkjet technology while avoiding design and decoration pitfalls. New industries, such as plastic profiles in the building sector and vinyl flooring manufacturers, are exploring inkjet to enhance efficiency, expand their product offerings, and adopt more sustainable production methods. Participants should have a basic understanding of inkjet technology, but the Academy provides in-depth insights tailored to specific application areas. Future Trends and Innovations in Inkjet Printing Are there already trends or technologies that you consider to be game changers for the industry? Kammann: Sustainability and efficiency are driving major innovations. One of the key developments is the shift toward non-toxic, aqueous-based inks for non-porous substrates like plastics. While further advancements are needed to fully replace traditional UV-curable or solvent inks, this transition is crucial for improving recyclability and environmental impact. Another significant trend is energy efficiency, particularly the move from traditional mercury UV curing to UV LED curing. This change not only reduces energy consumption but also enhances process sustainability, making it a key focus for the industry. How important is K as a platform for introducing innovations such as inkjet technology to an international audience? Kammann: K is the leading trade show for the plastics industry, making it an essential platform for showcasing advancements in decoration technologies like inkjet printing. While decoration is a smaller part of the exhibition, K provides a focused environment to present new products, techniques, and technological breakthroughs to a highly relevant audience. Recent editions of the show have highlighted growing emphasis on sustainability, with key topics including recycling, eco-friendly products, energy efficiency, and carbon footprint reduction. These themes will continue to shape discussions at the upcoming event, reinforcing the role of inkjet technology in driving both innovation and sustainability in plastic decoration. ESMA Academy: Inkjet for Plastic Applications Date: 31 March – 3 April 2025 Place: European Centre for Dispersion Technologies, Selb Programme and registration: esma.com/academy Elena Blume (Editorial team K-Mag) More around Materials Design

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  • Jogging shoes and co.: plastics in sportswear

    Exclusively for K-Mag 31.07.2024 The right outfit for every sport - what was long the preserve of competitive athletes has now become an integral part of leisure sports. Even for a short jog after work, sports enthusiasts can access sophisticated equipment. From breathable sports shirts, cooling or warming (depending on the season) running tights or running shoes with a medium or high drop, for overpronation or not. The choice is varied and sometimes difficult. However, there is one unifying factor that most models have in common, whether shoe or cap, trousers or jacket - plastics are used in their manufacture. Plastics and their special properties The use of plastic in sportswear is due to its diverse properties, which make production easy and enable the desired results to be achieved. Jogging shoes/running shoes, for example, can be made particularly light and flexible by using plastic foams (often EVA or TPU) in the soles. When running, they can absorb the impact forces well thanks to a good midsole to relieve the heel and knees or also return the energy to the runners, which is particularly desirable in competitive sports, for example. (Although not always permitted, see box below). The synthetic outsole in turn ensures that the shoe is waterproof and durable. The upper itself can be customised to meet specific requirements by using different materials: breathable, waterproof, warming or cooling. In addition to synthetic materials , wool is also used here. How the Nike Vaporfly amazed the marathon world A few years ago, the Nike Vaporfly made a name for itself in competitive sports (see Ineos 1:59 Challenge ). In 2019, runner Eliud Kipchoge became the first person to run a marathon in just under two hours (not an official world record as it was a test run!). He had his shoes to thank for this, among other things. The Nike Vaporfly were characterised by a particularly thick, 40-millimetre sole. A carbon fibre plate improved the runner's energy efficiency by making it easier to push off from the ground and promoting forward movement. In addition, Nike used a special ZoomX foam in the midsole, which provided exceptional cushioning and energy return, reducing fatigue and increasing running performance. The advantages over other shoes were so immense that the competition shoe in this form was banned by the World Athletics Association in 2020. It is also no longer permitted to wear test shoes, only models that have been on the market for four months. Plastics in sportswear: it's all in the mix In sports shoes in particular, consumers cannot always know exactly which plastics are used, as manufacturers sometimes give their own names to their plastic soles etc. Company secrets and patents developed for production play a role here. However, general information on the materials used does exist. It is clear that modern jogging shoes use materials such as ethylene vinyl acetate (EVA) and thermoplastic elastomers (TPE). Thermoplastic polyurethane (TPU) is another popular material that is valued for its high flexibility and durability. TPU is often used in midsoles and outsoles to improve both the durability and performance of footwear. It enables optimal energy return, which can contribute to a more efficient running style. 3D printing is also increasingly being used in the manufacture of sports equipment. Professionals are usually the driving force here, as adjustments to weight and structure - be it the running shoe or the precisely fitting shin guard - can ensure better performance. Lightness and sustainability united Copyright: On AG The company On from Switzerland has presented a completely new application for the upper material of running shoes just in time for the 2024 Olympic Games. A running shoe that is sprayed! The Cloudboom Strike LS has been under development since 2018 and Kenyan runner Hellen Obiri won the Boston Marathon in a development version in 2020. However, she is likely to attract a lot of attention when she competes in this model at the 2024 Olympic Games in Paris in August. Made from just seven parts, the midsole, which consists of a special Pebax mixture called Helion ™ HF hypofoam, is sprayed onto a blank foot in three minutes using the so-called LightSpray™ method, without the use of adhesives and like a spider's web. The shoe is then put on like a sock and should fit the foot perfectly. Weighing between around 160/170 grams (depending on shoe size), the shoe is a real lightweight. If you happen to be in Paris: On will be showing a live production of the Cloudboom Strike LS at the ‘On Labs Paris Pop-up’ at 27 Boulevard Jules Ferry in Paris for the Olympic Games in Paris until 10 August. You can find more information on plastics in the textile industry in this article. Circular economy: environmental issues are moving more into focus Almost everyone has fleece jackets like this in their wardrobe. They are now often made from recycled plastics. Copyright: envato To improve their environmental footprint, more and more manufacturers are turning to recycled plastics made from recycled PET bottles or other plastic waste. Recycled polyester is familiar from fleece jackets, for example, but is also used for sports T-shirts or sports trousers. Modern recycling technologies now make it possible to produce high-quality plastics that offer the same performance and durability as new materials. Together with more sustainable production methods, the ecological footprint can be improved. Unfortunately, it is not yet possible to produce a complete closed-loop system. Depending on the production process, it may not be possible to separate the plastics - for example in an upper - by type. Bio-based plastics from renewable raw materials Bio-based plastics , which are made from renewable raw materials such as maize, potatoes or sugar cane, are also becoming increasingly important in sportswear production. Modern manufacturing processes make it possible to produce bio-based plastics with outstanding technical properties and are therefore being used more and more. All in all, there are some very exciting developments in the field of sporting goods and their manufacturers, which are likely to hold one or two surprises in store for us. One thing is certain: plastics will definitely be part of this development! Who thinks of asparagus when they think of bio-based plastic? Find out more in the interview! Exhibitors & products around plastics processing Processing technologies Follow on treatment of plastics products Supplying Product groups Products To all exhibitors in this category Simone Ernst (Editorial team K-Mag) More about plastics in everyday life

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  • Rubik's Cube turns 50: A plastic cube that keeps the world spinning

    From ABS plastic to recycled materials Exclusively for K-Mag 11.09.2024 U' L' U L U F U' F' – doesn't mean anything to you? And yet you have most probably already followed this pattern: when trying to solve the Rubik's Cube. The plastic cube is celebrating its 50th anniversary this year. Originally made of wood, it is now of course made of plastic (some of it even recycled) and is as popular as it was on its first day. From today's perspective, it is hard to imagine that it took six years to develop the small cube. But where rapid prototyping, fused deposition modeling and the like make development easier for us today, in the past there was nothing like that. The cube had to be designed and built by hand. In 1974, Hungarian Ernő Rubik developed the Rubik's Cube, which has been world-famous since the 1980s and bears his name. Rubik built the first models out of wood. When the cube went into mass production, the manufacturers switched to acrylonitrile butadiene styrene copolymer (ABS) and injection molding. After the black individual parts were produced and assembled, they were covered with the typical colorful stickers made of polypropylene film. The design is as simple as it is practical. The cube has never really gone out of fashion since the 1980s. The cube was developed at a politically difficult time. While it became a bestseller in its native Hungary through word of mouth alone, sales on the other side of the Iron Curtain were difficult. According to the inventor Rubik (who, incidentally, was a professor of architecture), it was simply too complex in the eyes of Western companies. A toy that only a fraction of buyers would ever solve? Not interesting. Plastic often makes history and becomes a real classic. The Bobby Car has also already celebrated its 50th birthday. Click here for the article. The German toy manufacturer Schleich is also moving with the times and is pursuing an ambitious sustainability project. Get to know more about that here. One company finally took the risk and estimated the sales figures (then optimistically) at one million. They just missed the mark: the plastic cube was sold 30 million times worldwide in its first year. To date, the Rubik's Cube has been sold almost 500 million times - approximately 52 times the current population of Hungary. Today, the Rubik's Cube brand belongs to Spin Master and is moving with the times when it comes to plastic. In addition to the many cube variants made of conventional plastic, Spin Master has developed the Rubik's Re-Cube made of 100 percent recycled plastic, thus taking a major step towards sustainability in the plastics industry. It is made from 100 percent recycled plastic. But that's not all when it comes to sustainability: in 2021, Spin Master Corp. in the USA teamed up with the company TerraCycle to make the cubes more recyclable. If the cube is no longer wanted, it can be sent to TerraCycle. There it is melted down and then processed into park benches, for example. And what is the cryptic combination "U' L' U L U F U' F'" all about? Quite simple: 'Cubes' use such letter combinations to note down the respective movements. The letters stand for the side of the cube to be moved (U for Up, L for Left, F for Front, etc.). An apostrophe is added when the side is turned counter-clockwise. Mathematicians racked their brains for decades over the shortest solution for the Rubik's cube, the so-called God number. Got a taste for it? So that users don't despair after the first turn, there are numerous instructions on how to solve the cube. The official Rubik's Cube website also provides a guide. Click here for the guide. The God number describes the ideal solution to a mathematical problem. In the case of the Rubik's Cube, this means solving the cube with as few turns as possible. The difficulty for the mathematicians lay in the number of possible combinations. There are 18 possibilities for the first move with the cube, then 18 more for the next move, and so on. This results in 43 trillion different positions. In 2010, German mathematician Herbert Kociemba and Californian computer scientist Thomas Rokicki proved that the number of God is 20. Apart from the recycled plastic, the Rubik's Cube is also moving with the times in terms of digitalization. It is also available with Bluetooth so that an app can track every movement. But whether old-school or modern: The Rubik's Cube has been delighting people for decades. Incidentally, it took its inventor over a month to solve it the first time. So don't worry if you also aren't successful in your first few spins. The Rubik's Cube in numbers Records: Max Park solves the cube in 3.13 seconds in 2023. A robot from Mitsubishi Electric Corporation takes just 0.305 seconds Size: The most complicated Rubik's Cube is 21x21 squares. Solution: There are 43 trillion ways to solve the Rubik's Cube. You could cover the earth 200 times with this number of Rubik's Cubes. Documentary: In 2020, Netflix released the documentary "The Speed Cubers". Max Park is also one of the protagonists here. Pop culture: The Rubik's Cube also appears in films time and again, for example in 2012 in "The Amazing Spiderman" with Andrew Garfield, in 1998 in "Armageddon" or in the animated children's film "Wall-E". Kyra Molinari (Editorial team K-Mag) More about plastics in everyday life

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  • Rendering packaging sustainability transparent with blockchain technology

    Blockchain technology can revolutionise recyclate traceability. Copyright: biasciolialessandro 30.12.2024 How much recycled plastic is really in a given product? Maximum transparency is a fundamental factor to achieve quotas and sustainability targets, whether it's in terms of consumers, authorities or the manufacturers themselves. Manufacturers who want to disclose how much plastic recyclate is actually used in packaging can only do so if they include the entire value chain. This is a complex challenge. Blockchain technology offers an innovative solution as it allows for seamless tracing along the entire value chain. Challenges along the value chain The complex international value chains represent a significant obstacle to using recycled materials. On the journey from waste to new packaging, there is always the risk of materials being contaminated or replaced by lower-quality plastics. This makes it more difficult to verify whether companies are actually complying with their disclosures regarding the proportions of recycled material. Blockchain technology may open a path to more transparency and traceability. Even more, it could be a game changer. It provides a decentralised database that documents all transactions along the value chain. Each movement of materials and each manufacturing process can be digitally recorded to reassure companies and consumers that the final packaging only contains certified recyclates. How blockchain secures recyclate traceability There are various possibilities for blockchain technology to be used in the packaging industry in order to ensure the traceability and ultimately the certification of recyclates. It offers seamless transparency in the packaging industry. The digital recording of each single movement and change of materials creates an unalterable record. This is accompanied by digital certificates that can be issued for each batch of recyclates. These certificates contain information on the origin and quality of the material. In the blockchain, the certificates can be checked for all supply chain actors. Another characteristic of this technology is the linking of physical materials and digital data through technologies like RFIS tags, QR codes or other identifiers. This allows each packaging unit to be clearly identified and traced along the value chain. Exhibitors & products around recycling Recycling plants Separating and sorting systems for waste Size reduction equipment (crushers, shredders, grinders) Compounding lines Recyclates Best practices for traceability: Plastic Bank and Veolia Companies like Plastic Bank and Veolia, who are using blockchain technology successfully to ensure the traceability of plastics and recyclates, show us how it's done. The Canadian social enterprise Plastic Bank uses blockchain to collect and recycle plastic waste in developing countries. The collected waste is recorded in a decentralised database and the waste collectors are awarded digital tokens for their work. To ensure that the origin of the recycled materials can be traced seamlessly and transparently, every transaction is recorded in the blockchain. This guarantees that the certified recyclates are the plastics that were actually collected and that they have not been replaced by new plastics. The French recycling company Veolia also relies on this technology. The company uses blockchain to monitor the origin and purity of post-consumer plastics along the entire recycling chain. To trace every batch from collection to processing into granules, Veolia combines blockchain and RFID tags. A pilot project in Germany has shown how systems based on blockchain can increase transparency and better control recycling rates. Blockchain for the certification of sustainable packaging If packaging must meet specific quotas and comply with statutory provisions, this process can be made transparent and also certified via blockchain. For instance, the proportions of recycled material can be proven. Reusable systems are another area of application. Here, blockchain technology can document the number of reuses and the condition of the packaging to ensure efficient traceability. Blockchain can also support the entire life cycle of packaging by making disposal and recycling traceable in end-of-life management. Legal requirements and greenwashing prevention In light of new statutory requirements for the traceability and certification of recyclates, for example issued by the European Commission or the US Food and Drug Administration (FDA), the blockchain can support companies in fulfilling their documentation duties. This enables compliance with these regulations to be monitored in real time and manipulation to be prevented. And in return, regulatory authorities might find it easier to check companies' disclosures regarding recycling quotas and proportions of material. This would make promises of sustainability more credible and prevent greenwashing. Blockchain as a driver of circular economy Blockchain technology has the potential to fundamentally transform the packaging industry. It offers transparent traceability of materials and builds trust in the authenticity and quality of recyclates. Projects like those of Plastic Bank and Veolia show that the use of blockchain in recycling is already possible today. With increasing technological maturity, the blockchain could become an indispensable building block of a transparent circular economy and ensure the traceability of recyclates in the long term. Source interpack SPOTLIGHT More around Packaging

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Topics covered 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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