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 (111)

  • Plastics make the mannequins’ world go round!

    Stefanie Hütz (exclusively for K-MAG) © Uschi Fellner 22.05.2020 Display mannequin manufacturers have not only been creative in terms of design. Resource-saving operations have also ranked very high on their agendas for years. There has been in-depth research in developing materials and processes and plastics continue to play a leading role. Fashion retail without display mannequins would not be the same, they are the eye-catchers when window shopping, provide sales-promoting stimuli and make brand statements. Their designers view themselves as artists rather than suppliers to the fashion sector. But which materials are used to manufacture display mannequins to start with? Glass fibre has proven its worth The ecological footprint also plays an important role in mannequins. Bonaveri Eco Mannequin_SKY lr by Armin Zogbaum, © Bonaveri The selection of materials is determined by the target group to be addressed and the price level to be targeted. The “traditional” portfolio of materials ranges from glass-fibre reinforced plastics, polyurethane, ABS and blown polystyrene to polyethylene, polypropylene and paper mâché. Susanne Oelmann, Managing Director of Brigitte Oelmann, the exclusive representative of Italian mannequin specialist Bonaveri in Germany, summarises the various uses with examples: “For major campaigns mannequins in polyethylene are a suitable option being comparatively low-cost. For small series with high demands made on individuality producers give preference to fibre glass.” Dr. Josef Moch, Managing Director of the German company Moch-Figuren, who visits the K trade fair regularly to learn about new manufacturing methods, moulding techniques and materials, explains: “Our mannequins stand out because they are easily adaptable to trends. This means they are easy-to-handle and we can change production moulds like those for fibre glass. Around the globe the glass fibre mats – usually soaked with polyester resin – are manually placed in the mould and allowed to cure there. Other materials such as PP, PS or ABS require more sophisticated production moulds, made of metal most of the time.” Deceptively real!! Mannequin fromHans Boodt. © Hans Boodt Alluding to the sustainability debate, which is also very intense in this sector and not always produces unambiguous results in view of its complexity, Andreas Gesswein, CEO of Genesis Display, also Germany, says: “Glass fibre has received some unfair criticism here after manufacturing was done illegally in some parts of the world and at times under disastrous conditions without protecting the employees.” Genesis Display has put the materials and processes to the test in a concerted effort with the Fraunhofer Institute. “In the final analysis these tests confirmed that glass fibre – when properly processed – is still the best composite in combination with organic resin.” Dr. Josef Moch refers to the fact that “fibre glass is completely recyclable now; it is shredded and its granulate used in cement production to improve the ecological footprint.” Nevertheless, Moch-Figuren is working on “a reduction of material consumption by using higher-quality resins with more elasticity. This makes it possible to reduce wall thicknesses”. Genesis Display produces its mannequins with almost 50% organic resin admixture today. Andreas Gesswein points out: “We were the first producers worldwide to cooperate with DuPont Tate & Lyle BioProducts to use an organic resin from maize plant residuals not fit for animal feed.” Tests have already been carried out and productions run with natural fibres such as coconut, hemp, cotton, sisal, bamboo and flax. “With viscose fibres and recycled polyester fibres as glass fibre alternatives we have produced especially positive results.” At Hans Boodt Mannequins from the Netherlands an organic composite material comprising 53% organic resin and 12% fibre glass is already considered the standard today. In part the fibre glass admixture is replaced by jute and the like here, too. With an eye on the complete life cycle There are no limits to the imagination. Genesis Display, © Uschi Fellner Bonaveri commissioned the Technical University of Milan to carry out a lifecycle analysis for its complete display mannequin production. “It became clear here that the base material is of the highest relevance for the environment.” This is why in just under four years of research time the bio-based “BPlast” polymer was developed, of which 70% consists of a certified cane sugar derivative and which is completely bio-degradable. “With a view to the total lifecycle we managed to improve the CO 2 -footprint by 25.72%,” delights Susanne Oelmann and announces: “Bonaveri will continue doing research in bio-degradable plastics.” In contrast to this, Dr. Josef Moch rejects the use of organic plastics. With reference to publications of renowned organisations he sees risks associated with nutrient cycles, ground water and soil. But he also approves of Susanne Oelmann’s sentence: “Plastics have been and will remain the material of choice for mass production.” This view is also shared at Hans Boodt where developers break new ground time and again, working with granulates from footwear production or experimenting with coffee grounds. For polyester they established a closed-loop system. The shredded material is used for manufacturing new mannequins 1:1. Hans Boodt takes back his mannequins as a matter of principle and has established both an “End of Life” and a “Second Life Program”. Moch-Figuren has given a second life to thousands of second-hand mannequins with facelifts and new paint. For the future, Genesis Display also bets on such new technologies as 3D scanning, 3D sculpting and 3D printing. At Hans Boodt’s company samples and smaller orders are already handled by 3D printing. However, Cornel Klugmann, Country Manager for the D-A-CH region, sees a particularly high sustainability potential in “producing locally, with short transport routes, i.e. in establishing manufacturing sites all over the world and also sourcing the raw materials locally if possible.” China is still the major producer country but the long way to Europe by ship goes hand in hand with high CO 2 emissions. This is why we cooperate with manufacturing sites in Europe, South America and Asia.” Stefanie Hütz, free lancer More around Plastics in Daily Life

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  • Using circular economy principles to recycle toys

    Interview with Johanna Bialek (Co-founder), Fridolin Pflüger (Co-founder), Felix Schulz (Co-founder), Roman Maletz (Waste management specialist), Florian Schinagl (Content Manager), HolyPoly GmbH Exclusively for K-MAG Slinky toys are a popular children's toy that appear to be able to run up stairs or delay their free fall. Source: Philotheus Nisch 28.12.2021 Many of us are familiar with this scene in our children's bedrooms: when the kids have outgrown their toys, the latter typically get boxed up until we finally take heart and purge them. But it doesn't have to be that way: the initiative of the HolyPoly company takes recycling steps to create new toys – that look slightly different. In this interview, the founding members and employees of the Dresden startup explain the steps it takes to recycle toys, talk about the partners they found for their project, and reveal how the new products can benefit children in a different way. The HolyPoly team; Source: HolyPoly GmbH What is HolyPoly's objective? Johanna Bialek: We work towards a world where using recycled plastic to make new products has become the norm. The goal is to create high-quality products that are made from 100 percent recycled materials and that are 100 percent recyclable. Fridolin Pflüger: We help brand manufacturers to overcome the respective challenges and thrive in our changing times. Why has plastic recycling been so difficult? How does your company plan to change that? Roman Maletz: Recycling per se is not that complex: you can use a preprocessed, high-quality plastic waste stream of known origin to make products that are equivalent to those made from primary material and that meet the complex requirement profiles for the wide variety of plastic products. The challenge is to provide a high-quality waste stream. This can be done by separating and measuring the various kinds of plastic in the waste stream. However, there are many products that are not (or cannot be) returned to reusable waste streams. Exhibitors and products around machines for recycling: Size reduction equipment Screening machines Pelletizers Recycling plants Plus, the plastics industry is still tentative as it pertains to the switch to recycled content products. HolyPoly supports brands that want to take the next step into a circular economy with their companies. We start by scoping circularity, exploring the possibilities of a specific application, and developing concepts that address the challenge. But we don't stop there: We assist our customers all the way through implementation, ranging from sourcing and preparing the material, design and engineering, to finished product, which is ideally also recyclable. Can you tell us about your PlayBack project? Florian Schinagl: Since May 2021, the toy company Mattel has taken back broken or discarded toys throughout Germany to give them a second life. The recycled toys will be used to create playground equipment that will be donated to a children's facility. Our program supports Mattel in its goal to achieve 100 percent recycled, recyclable or bio-based plastics materials in both its products and packaging by 2030. Felix Schulz: HolyPoly is presently managing the PlayBack project in Germany: handling process design, waste management legislation, logistics planning, recycling process coordination, public relations, as well as product development and playground production based on the collected old toys. First, the plastics are sorted and shredded. Source: HolyPoly GmbH What is the general process that turns toys into a new product such as playground equipment, for example? Schulz: We first procure the material we need to make the new products. For example, private households mail material to us free of charge using shipping labels they can create on the website. We also collect material from residential sources such as schools and day nurseries. A certified recycling company subsequently documents and checks the materials. The recycling process starts right here, which includes crushing, sorting, cleaning, processing, and recovery of non-recyclable components. Separating materials by type is a major challenge in this setting, as the collected toys are often mixed-material products. Design for recycling is a strategy that would make this process easier and more effective in the run-up. This is followed by the required materials testing. The recycled material then becomes the foundation for the concept, design, and construction of the playground – we call this design from recycling. The final step is to use the material and create the new product. Subsequently, the recycled material can be put to a new use. Source: HolyPoly GmbH What have been your project successes thus far? Pflüger: Initially, the program caused quite a stir in the toy, plastics, and recycling industries. It is obvious that it was carefully designed and merges sustainability communication with the R&D cycle – making it a genuine pioneering project. It takes active marketing to reach out to end users – as Germans are not yet used to mail-in programs. After the first few months were off to a slow start, mail-ins have seen a sharp increase since September. We expanded the program with the residential collection and pickup at day nurseries and schools in early December and hope to see a further increase as a result. Source: Philotheus Nisch What are your goals for next year? Maletz: During our first year, we supported many brands in a wide variety of industries, including fashion and medicine. Now we want to scale these projects as it pertains to the number of customers and recycled materials, allowing us to make a valuable contribution to resource conservation and greenhouse gas emissions reduction. Pflüger: Our first mass-produced products will be available on the market, which is a major milestone. We will also add effective communication to send a clear signal and get the message across that sophisticated products groups and material flows can embrace the principles of the circular economy. From a recycling perspective, we also consider investing in larger facilities besides our development center in downtown Dresden. Kyra Molinari (Editorial team K-MAG) More around Plastics in Daily Life

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  • Röchling BioBoom: bioplastics make cars greener

    Interview with Fabrizio Barillari, Senior Product Manager Battery Components & Biopolymers Global, Röchling Automotive S.r.l. Exclusively for K-MAG Source: Röchling Automotive 27.07.2021 Alongside many other industries, the automotive sector is also moving in the green direction. Electromobility is booming. However, plastics produced from non-renewable raw materials such as petroleum are also installed in e-cars. Röchling Automotive has recognized the need for bioplastics that meet the high requirements for automotive applications – and has developed BioBoom. Fabrizio Barillari; Source: private In an interview with K-MAG, Fabrizio Barillari talks about the demands placed on materials for the automotive industry, why Röchling BioBoom is not a competitor for food supply chains, and how the company is committed to climate protection. Mr. Barillari, how did the development of Röchling BioBoom come about? Fabrizio Barillari: We already had the idea for this at the end of 2009/beginning of 2010 together with an external partner with whom we have been working for several years. At that time, we already saw a future for such non-petrochemical solutions and started with the first developments. Today, the market is open to it, and we are increasingly receiving explicit requests from our customers for precisely such biomaterials. What is the bioplastic made of? Barillari: At least 90 percent of Röchling BioBoom is based on ingredients obtained from sugar cane and sugar beets, for example. In the future, we may even use cellulose for this purpose. These ingredients are renewable and at the same time available in large quantities. It is important to mention that we are not in competition with food supply chains. The raw material is only for industrial applications and cannot be used for food. The sugar goes through various chemical processes, and in the end we get a raw material that contains polylactides (PLA). Finally, we add small amounts of additives, resulting in our Röchling BioBoom. Why this was necessary is actually quite simple: PLA is biobased and also biodegradable. This is a strong advantage of the material, but in its form it is not yet optimal for automotive applications. The automotive sector has very high requirements in terms of service life or mechanical forces. That's why we have developed our own additives that allow us to keep the biobased properties without compromising our customers. Where is the material used everywhere? Barillari: We can offer about 70 percent of our entire product portfolio with our bioplastic. This includes intake systems for combustion engines, active aerodynamic components, underbody protection, structural parts and so on. We are currently still working on tank and cooling systems and are confident that we will be able to offer a bioalternative here as well in the near future. Exhibitors and products around raw materials and automobility Polylactide Polypropylene Rubbers Plastics products and parts for automotive What challenges did you face in developing Röchling BioBoom? Barillari: We said right from the start that we didn't want to compromise when comparing bioplastic with petrochemical solutions. With our experience and our customers, we put together a set of specifications that is basically a sum of the most difficult tests we see our customers doing. That was the reason for the development. We saw: These are the results we need to get. We then compared those with the basic data of the raw materials and with that we progressively developed it that way. Source: Röchling Automotive What are your sustainability goals for the coming years? Barillari: The entire Röchling Group has a very clear strategy in this regard. We want to be one of the pioneering suppliers of plastics made from biomaterials by 2035. Our bioplastic is already on the market now and we have received our first orders, but we also want to develop this area progressively. We want to bring a bioalternative to market for every product we manufacture, so that we will have to use less and less petrochemical materials in the coming years. What responsibility do you think the automotive industry has when it comes to environmental and climate protection? Barillari: We are seeing all our customers moving in this direction and pursuing the goal of producing in a climate-neutral way. But not only that – more and more is being recycled and new, alternative raw materials are being used. These demands are also being placed on suppliers by vehicle manufacturers. The entire supply chain through to production is to become climate-neutral in the next ten years. This can be achieved, for example, by using renewable raw materials and climate-neutral energy methods such as solar panels or hydro-electrics. However, it is not just demands that are being made and targets that are being communicated; intensive work is already underway in a wide range of research groups. For example, life cycle assessment requirements are being looked at for each product and calculations are being made to determine how far we are from climate neutrality there. The next steps can then be evaluated and tackled. Elena Blume (Editorial team K-MAG) More around Mobility

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  • Benjamin Von Wong: "I make your impact unforgettable."

    How carelessly disposed and unrecycled plastic can become a problem, the artist Benjamin Von Wong shows in his impressive works made of plastic bottles, cups and straws. Exclusively for K-MAG 08.07.2021 We love plastic. It is versatile, lightweight, durable – and sustainable, as long as it gets recycled or reused. Carelessly discarded in nature, (disposable) plastic products not only give the material a bad image, but above all lead to massive environmental problems. This is precisely the issue that Canadian artist Benjamin Von Wong has addressed by drawing attention to these problems with impressive installations. Every single day, millions of plastic takeaway cups are used in food centers across the world. That has become so commonplace that we don't even think twice about it. To help start that conversation, the artist Benjamin Von Wong decided to create an art piece made from 18,000 plastic cups collected over the course of just a day and a half. These cups, collected from two dozen hawker centers across Singapore had to then be cleaned, arranged and assembled into an art installation with the "Plastikophobia". Although the word "Plastikophobia" doesn't officially exist in any dictionary, Von Wong and his team felt like it represented how they felt about single-use plastics – an extreme aversion to it. Hoping to draw a connection between how the plastics that we consume on land inevitably flow into the ocean, they decided to create the illusion of a diver swimming in an ocean full of plastic. Blog post: "This cosmic cave is an Instagram trap made from 18,000 used plastic cups" "When Starbucks announced that they were removing straws from their stores, we designed the Strawpocalypse out of 168,000 straws collected off the streets to explain why." – Benjamin Von Wong "It's just one straw, said 8 billion people." Sounds like a cliche little quote – but there is a lot of truth in it. Straws are not recycled in most cases. They're also one of the easiest products to turn down at a bar, cafe or restaurant. For his project, Benjamin Von Wong wanted to encourage people to turn down their next straw by creating a "strawpocalypse". The result was a 3.3m (10 ft+) tall art installation representing the parting of the sea to reveal the plastics hiding within. Although the installation is made from straws, it isn't just about straws. It's about taking a first step towards paying attention to the problem threatening the oceans we rely on. If things don't change by the year 2050, there could be more plastic than fish in the sea. While statistics like that can appear daunting and impossible to fight against, it all starts with small simple actions. Blog post: "'The Parting of the Plastic Sea' an installation made from 168,000 used plastic straws" "When TOMRA wanted to make recycling interesting, we created a mermaid drowning in a sea of 10,000 plastic bottles." – Benjamin Von Wong Worldwide, nearly 500 billion plastic bottles are sold every year – that's no less than 1 million every minute! Only 7 percent of those get recycled. Those are shocking numbers, but Benjamin Von Wong knew he wanted to make the problem more interesting somehow to draw attention to it. For his project, he borrowed 10,000 bottles from TOMRA Recycling. On his own, he was just a photographer – but thanks to the help of many supporters, he turned this lifeless pile of used trash into a message: #MermaidsHatePlastic Von Wong's hope: to spark a conversation about it and encourage people to take the pledge to reuse. Blog post: "10000 plastic bottles, one mermaid and a single wish" Why throw plastics into the ocean? Benjamin Von Wong und sein Team decided to throw an entire truckload of plastic into the ocean after they learned about this shocking statistic: "Every 60 seconds, the equivalent of a truckload of plastic enters the ocean." In his project he wanted to illustrate how plastics inevitably flow from land into the sea, despite our best efforts to stop them. The project was supported by Greenpeace Greece and local grass-root organizations like Garbage Art Corfu. Ultimately they collected over ten thousand pieces of plastic! Although they were able to remove the plastics that they put in, the same can't be said for what is currently happening every minute for the rest of our lives, and those of our children. #TruckloadOfPlastic is a call for responsibility – to consumers and to companies. Blog post: "Every 60 Seconds, This Much Plastic Enters The Ocean." Change happens when individuals come together to fight for something they believe in. You want to be a part of it? Images are available for licensing or create your own custom unforgettable campaign with Von Wong. Please contact: Suzy Johnston Email: suzy@suzyjohnston.com Tel: +1.416.863.5115 Web: www.suzyjohnston.com Benjamin Von Wong's blog contains the story behind each project View his portfolio here Elena Blume (Editorial team K-MAG) More around Materials Design

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  • A German plastic success story: the Bobby-Car turns 50!

    Exclusively for K-MAG The Bobby Car has been with us for 50 years and has seen many changes. Source: Simba Dickie Group 09.02.2022 Bright red bodywork, a white steering wheel and a lot of noise when driving: That's what the Bobby-Car is all about. Almost everyone knows it and almost everyone has owned one. Or still does. Generations of children have loved it, and just as many parents and neighbors have probably cursed it – whether because of the tattered shoes or the noise level. The Bobby-Car turns 50 this year and is one of the best-known plastic products from Germany. It all started in 1972: that was the year the Bobby-Car was introduced at the toy fair in Nuremberg. And even though it was ridiculed at first because of its ergonomic seat shell, today every child – and every adult – knows it. Since 1972, more than 20 million of the cult cars have rolled off the production line. Initially, it was manufactured at the production plant in Fürth until a major fire broke out there in 1998. The toy manufacturer BIG was able to recover from this setback relatively quickly, so that the slide car still inspires generations today. Today, the Bobby-Car factory is located in Burghaslach in Bavaria and the family-owned company BIG has been part of the Simba Dickie Group since 2004. Careful production for carefree driving pleasure If you take a closer look, the Bobby-Car is also a plastic success story: polyethylene granules are first dyed typically red before being melted into a viscous mass at 200 degrees Celsius. For each vehicle there is a mould into which the soft polyethylene is inserted as a tube and then inflated until it fits the mould. Source: Simba Dickie Group Large torches are then used to smooth out any unevenness so that there are no more edges or splinters that children could injure themselves on. After the axles, steering wheel, tires (made by injection moulding) and the typical stickers are attached, the vehicle is again treated with heat to ensure that everything holds properly. There is hardly any waste due to rejects. If defects do occur, the rejected material is returned to the beginning of the production cycle and recycled. Over the years, the Bobby-Car has of course been further developed and some features have been added. These include, for example, new designs, push rods, steering wheels and whispering wheels that finally spare the nerves of parents and neighbors. But no matter whether it's quiet or loud: The red polyethylene vehicle is known everywhere and has become an icon over the years. Driving fun connects – across generations Source: Simba Dickie Group The little red racer inspires not only children, but also adults who have remained young at heart. Today, there are enthusiastic Bobby-Car racers and collectors, some with over 300 exhibits. And there really is a lot to collect: The company now offers more than 100 different models, from Porsche designs to police cars, there is something for everyone. The races, which are organized by official clubs, are fast-paced: up to 100 km/h are possible on the downhill tracks. And if you can't go fast enough on a classic Bobby-Car, or if you want to be safer, you can even tune your little racer accordingly. So nothing stands in the way of reaching the top of the world rankings (yes, they really do exist). If you like it a bit more cozy and want to feel young again, you can go down to the basement or garage, dust off the little iconic car and take it for a spin down the driveway. Pure nostalgia! Kyra Molinari (Editorial team K-MAG) More around Plastics in Daily Life

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  • The Future of Design Is Designers Envisioning Not Just the Product, but Its Next Life

    Interview with Chris Bangle Exclusively for K-Mag Copyright: Chris Bangle Associates Copyright: Chris Bangle Associates Chris Lefteri Hi Chris, so, what are you up to these days? Chris Bangle I run a design consultancy, Chris Bangle Associates, in Northern Italy. We are about 10 people, and our workflow is mostly outside of Italy in fields that have to do with design such as product design, automotive design etc. It goes clear across the gamut of transportation and products. We also do a lot of workshops here that are for management, particularly things regarding creativity, brand design, managing creatives, etc. Then recently we have also begun to get into kids’ animation. This has opened up some worlds for us that we didn't know were relevant for design, but they are. Our research here ostensibly is to help create a fiction narrative that we try to animate. But in reality, it's helping us create a real-life narrative that we think is applicable to real-world issues. Chris Lefteri Thank you very much. Our studio recently had the pleasure of seeing a talk you did in Budapest. Can you give us an overview of this talk as it was very interesting? Chris Bangle Sure, some years ago, I was invited by the German government to participate in Potsdam in a particular event that was geared to understanding the coexistence between technology and humanity. The undercurrent thought was: “Will we survive it?” So, I was asked to bring a design point of view into it, and specifically address how design would address issues emerging from this co-existence. I specifically took to task the idea of the blue-collar worker, let's say the mass of people that the Industrial Revolution took out of the fields and put into factories. And as we've gone through subsequent editions of the Industrial Revolution, technology has developed so that it can and may replace those jobs entirely. The question is, what do these people do? Right? Copyright: Chris Bangle Associates Chris Lefteri Yes. Chris Bangle My premise was that this type of work turned out to be extremely engaging for a lot of people, it gave them something to do and raised incomes across the world. It provided meaningful employment to people. Now, I'm not saying this is the same kind of meaningful employment as if you were writing software every day or something like that, but for the vast majority of people who really enjoy getting paid to do eight hours of something and then return and have a life, it turns out that factory working is actually quite appreciated. Yet there are countries where we've taken factories away, we've taken the industrial base away from those countries and not replaced it with anything and therefore masses of people don't have anything to do. And the problem is somebody will always give them something to do and that something is not always a good thing. My thoughts on this were triggered by the Arab Spring Revolution that happened to coincide with the London riots. At the baseline of all the headlines is always “Disaffected Youth Sees No Future”. So, I wanted to address this specifically. (I'll come to the materials in a second here.) And so, I looked at it from the point of view of process. Just finding a piece of paper here. I like to draw on things. So, the premise is if you take a square and you say, “This is about things which are Predictable. And Precise in regards to process.” Obviously, things that are Very Predictable and Very Precise, this is where manufacturing gets taken over by automation the quickest, right? It affects the whole automation base; it spreads from there. You go down to this corner down here, and you have things which are Very Precise but Unpredictable. This is like surgery. You know, you don't know what you're going to find, but you better not make a mistake. You get up into a corner here, which is Very Predictable, but Very Imprecise. This is things like agriculture. You know you'll pick the apples on Tuesday, but you don't know where they are. Finally, you come down to this corner here, which is Unpredictable, and Imprecise. This is generally the service economy. This is healthcare, caretaking, stuff like this, right? So, basically, I said, if you look at the optimum solution, it would be to put in factories jobs which are Imprecise and Unpredictable because that's the last thing automation would take from people. Right? So, let's shift everything to there. Well, it turns out one of the jobs, which is Very Imprecise and Very Unpredictable, is disassembly for upcycling. Copyright: Chris Bangle Associates Chris Lefteri Yes! Chris Bangle It's taking shit apart, right? I guess in the days when everything is on Internet of Things and there's a coded number on everything, robots can also take it apart quite easily. I'm not saying that machines can't do everything. I'm just saying, that's probably a good spot to start to keep people engaged. Well, unfortunately right now, this stuff is farmed out, you know, we ship everything to Africa, we let poor guys work in the field doing this stuff. They're burning insulation off of wires to get at the copper. I mean, it's a horror story! All you have to do is follow Greenpeace on recycling and you get ill by what you're seeing there, right? So, the trick would be: “How do you get these guys paid well enough to do this?” Because just providing the materials alone isn't going to do it - the raw materials are just substituting something out of the material flow. The only way to do it is to not go as far to get to the raw materials itself, but stop at the subset. You stop at the parts themselves. That means if I'm going to recycle this [points to coffee maker], I don't grind it into aluminum. Because that wastes all the energy that went into the tooling to make it in the first place. What I do is, I take the parts that are usable, like this, and I use it for it for something else. I upcycle it. Copyright: Chris Bangle Associates Chris Lefteri But without destroying the parts? Chris Bangle Yes. I don't destroy it if it's still good, but the trick is if we upcycle parts, what are we upcycling them into? And the theory would be: we upcycle them into a new generation of products that can do something entirely different. So, the whole point behind this is you have to turbocharge the concept of upcycling. I mean, mega-mega-turbocharge it! And the reason why you're doing it is because you're employing people. That's really the base reason. This is super inefficient. This is a super non-holistic, super inefficient. Chris Lefteri You’re saying efficient or inefficient? Chris Bangle Inefficient! It's much more efficient to just burn this stuff. It's super inefficient, it's super non-holistic. You know, it doesn't give you pretty things, right. Of course not. You know, if I start combining the bottom of this coffee maker, with this glasses case, it's not going to look like an intentionally designed product? It'll work, but it won't look like it does now, right? Okay, so let me just finish the story here, and then you'll get where I'm going… The only reason it works is if you put it in an economic cycle, which makes it work. And fortunately, we have a very good example of that, and that is the zero emission credits that pay for companies like Tesla. Tesla, for the first years of its existence stayed alive selling credits to those gas guzzler companies, like BMW, Mercedes, etc., who had to pay for the credits or they would be fined tremendously by the government. So, carrots and sticks, right? So, what happened was they paid so much money into the Teslas of the world to make electric vehicles that they not only kept those guys alive, they turned them into a viable alternative for themselves. What did it cost the government to do that? It costed them nothing, because that's just carrots and sticks. The problem is, governments never know how to distribute money. But with carrots and stick like in the Tesla example, the money goes directly to the guys who give you the credits. So, who needs to get credits? These guys, who make things like cell phones. I’m going to go out on a limb here and say, probably with companies like that, social responsibility is not the highest thing on their priority list, considering the trillions that they make in revenue, okay? So, having these guys have to buy credits from the operations that are employing people to take stuff apart and have it put back together into other things, maybe it's not a bad idea, right? Economically, you could get it to balance out from that point of view. The other thing is: how do you actually do this? Like, how do actually put those two things together? Copyright: Chris Bangle Associates Chris Lefteri Right, because you're a designer, you're advocating non-design because it's about putting two different parts together. Chris Bangle Exactly. Okay, it only works if you use, let's say, AI to identify the parts, which are the closest to being part of it. And then you use the AI to design the interstitial parts, and you use some rapid manufacturing to connect the two. The idea is this type of design philosophy could never exist 50 years ago, because we didn't have a means to put these things together. Also, if you follow this concept to the next level, the next level is when you designed this coffee maker the first time, you didn't just design it to be a coffee maker. You were already thinking, “What's it going to be next?” This means we need designers who have a mentality to think beyond the immediate product into the next product and get it to work for both. This is a design revolution in many senses. In particular, why would people want to buy something that ugly? Okay, I'll come back to this one. So, we've proven over centuries that design can make you like anything. 10,000 years of “More is More,” and we convinced you in two generations, “Less is More”, okay? I mean, design can do anything with your brains. Once it becomes established that, if you don't buy into this new aesthetic, then you belong to the bad guys, once that's established, people will take this, they will accept it into their lives, even if it isn't this holistic, clean, likes-to-be-made-by-machine look. Copyright: Chris Bangle Associates Chris Lefteri So, are you advocating a certain kind of, I wouldn't call it “ugly”, but a certain reappropriation of how we evaluate what is good and what is bad? Chris Bangle Oh, absolutely. Absolutely. Because what you're trying to do at the heart of everything is make humanity viable. We have been convinced by Modernism to like what machines like to make. Hello? We've got to reverse this trend if we want to keep people viable. Now think of the upside of this in terms of materials. The upside is we're using less raw materials because we're giving multiple lives to what we do make. That's a wonderful thing. We're extending them. So, the upcycling concept is a wonderful starting place, but to make this work, we’ve got to really engage people. And this starts with a design mentality. Chris Lefteri So that role of the designer then changes into somebody who has to find some way to communicate that this has a value, right, because we buy into stories? Chris Bangle Exactly, and designers have got to work hand-in-hand with the AI to be able to put this stuff together. So, a designer can't have a too-fixed idea of what they want to have and say. They have to have a vague idea of what it's going to be and then the AI says, “Well, how about if we use this part? I think creativity will take a whole new vision. Instead of creativity being about what is the slickest, prettiest shape I can make? Come on. I mean, every day that goes by, the AI tools are demonstrating they can make slicker, cleaner shapes faster than we can do it. It's got to be, how do I build a story into it? Chris Lefteri Right, exactly. So, your vision is to remove the concept of material recycling and say that recycling is about repurposing rather than the embodied energy of having to break something down and then remake it? Chris Bangle Yes, I call it 2E, or Second Existence. Copyright: Chris Bangle Associates Chris Lefteri And how is that going to work with a car? Chris Bangle Well, I mean, you’ve got a really good challenge on your hands there. In fact, one of the first students who took this on wanted to use parts from, let's say, a washing machine, but he didn't like the washing machine parts as they were. He went back and redid the washing machine so that it would work as a washing machine, but then also as a car fender. And he wound up with a washing machine that was so absolutely surreal. Everybody who saw it said, “That's a cool washing machine. I really want to have that washing machine!” I mean, what can I tell you?, you know what I said, otherwise it would be a white box! Chris Lefteri I know that the plastics industry is suffering from a lack of skilled workers to operate machines and injection molders and that's something that the industry in Germany in particular is having to address, that no one's going into engineering… Chris Bangle There you go. I mean, particularly, one thing is the skilled workers on the line, the other one is the engineers to do it, right? The whole mechatronics industry in Europe, I think, took a shot in the knee when people decided that the only future is software. Now even the software people are turning towards atoms. The physicality of our world, I think, is poised to make a return in terms of importance. Copyright: Chris Bangle Associates Chris Lefteri You said that you do training for business leaders. Have any of them given you any thoughts, have you ever discussed this with them? Chris Bangle Well, this particular concept I'm very careful not to overly push onto companies because I think it's something the ground for which has to be carefully prepared for before somebody who's got a profit mind can walk on it. If you don't have the carrots and sticks in place, if you don't have the design mentality in place, if you don't have a communication mentality in place, you won’t reach the people doing a job where efficiencies and things like this are better than any other alternatives. They're not going to be able to react to this, in my opinion. That's why my audiences until now have been mostly designers. And luxury pioneers. I think luxury goods is the first that's going to feel this. You never want push to be your major selling point. You want pull. You’ve got to get it to be the pull. So, it's got to be what the cool people have. It's got to be what's in. It's going to be with the front end,etc. And that's why I'm saying, talking to business leaders about this is kind of distant from where pull happens. Chris Lefteri And that’s why luxury brands are a good starting point because they create that pull? Aspiration, pleasure? Chris Bangle Exactly. And they've already got one foot in art. And if we don't keep this artistic side of ourselves present in this, then we're going to lose another chunk of what it means to be human. And I think the luxury field in general is far more comfortable with the concept of art than let's say product design. Chris Lefteri Yes, because when we talk about the aesthetics of these new products, it does remind me of a lot of things that I've been seeing recently, where in the world of plastics and molding, the unfinished, the flow lines become very much part of that honesty, and that move away from perfection. Maybe we're not too far away from having products that are like the toys in Toy Story, the kid next door in Toy Story? Chris Bangle Right now, we’re working on workshops for creatives in the car industry about what it means to have an emotional connection to a car. Copyright: Chris Bangle Associates Chris Lefteri Right. Chris Bangle A lot of it has to do with character and character almost always is about a deviation from a norm, which could be found as an imperfection, but it often is something which is a negative. The first page of Harry Potter explains why Harry Potter isn't just a normal boy. He is, except he's got this scar across his forehead and instantly you have a recognizable trait for this character. And as we look at cars that we really love, we've noticed how many of these things embody some imperfection, some less than optimized solution. Yet, that's exactly what makes them memorable, exactly why somehow we hold onto those things. It's less about “We want to build a world of Frankensteins for the sake of building Frankensteins.” It's rather, “What is our idea of where character comes from?” Chris Lefteri Absolutely! Chris Bangle Going back to your question on how we translate this into training for business leaders. Can you imagine a day in the life of a designer in this 2E world? It would be completely different than the one that you and I know. And this is something that I'm trying to get across in management as well. That this idea that management in design is a linear process. Like: “I know where I'm going. And if you deviate from where I tell you to go, I will hammer you back into place onto that.” This is being replaced now by the type of management that says, “Okay, in general, we're headed this way, but we all know by the time we get there, the target's going to change. So, let's see, as you guys interpret this, where your flow takes us, and let's run with what you come up with.” And that'll get us to a better target than we could have described at the beginning. Copyright: Chris Bangle Associates Chris Lefteri It's a complete mind shift in the education, roles and skills of a designer. Chris Bangle Yes. When I brought up the point that we do research here, we're trying to understand this in such a way that it's actually discussable, teachable. We can say “Is this right, wrong, good, bad? How do we measure this?” These are all subjects, which in a true design research phase, we try to answer. One of the things that interests us very much is “How does this relate to the flow of energy?” Some years ago, Stefan Bartscher, who is the robotics expert at BMW, taught me a lot about how energy use is managed from a system's point of view, so that we can begin to look at things like recycling and upcycling from a different point of view than just the material per se. We begin to look at it differently in a much bigger picture. And that's super complicated, but more and more companies are beginning to like that. I think in the future, if we want to be a sustainable world, sustainable is not going to be just, “I throw crap away in the best way possible.” It's going to be a total cycle, but a total cycle from a much bigger mindset than we have now. Like the total cycle of this [points to coffee pot] is much bigger than we have now. I mean, I keep throwing to you this piece of coffee pot. You have this piece of aluminum, right? Whatever this is, some kind of special fusion metal made for foodstuffs, this stuff has got a hell of a lifetime. And it took real tools to make it that were not simple. Okay. So why should the only future of this be powder? Chris Lefteri Yes, absolutely. Before we end, I have one small question which I round up with. It is to ask you, what is your strongest memory of a material from childhood? And the reason that I ask you this question is that it showcases the value that we place on materials is often to do with how they change the way that we feel. Chris Bangle Well, I love the question, by the way. It’s basically wood because my father sold wood. He was an industrial sales representative for a wood company. Our house was always full of wood. Sawdust, the smell of wood, the plywood, the taste of the screws, you know, because my dad will always say, “You spit on it and I spit on it” and then he'd screw it in. So, there's this whole association of the smell of wood, the cut of wood and the texture, the splinters in my fingers and everything like this. Chris Lefteri Fantastic! 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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  • 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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  • 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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  • PackTheFuture Award 2023: These are the winners!

    Outstanding sustainable plastic packaging Copyright: IK Industrievereinigung Kunststoffverpackungen 12.05.2023 56 entries, 10 winners, 1 special prize and 1 honourable mention – that's the positive balance of the PackTheFuture Award 2023. The results were announced at the award ceremony at interpack in Düsseldorf. The award honours innovative and sustainable packaging solutions made of plastic. The PackTheFuture Award aims to promote and publicise the contribution of plastic packaging to climate protection, the Circular Economy and responsible consumption. The award is organised by the two associations IK Industrievereinigung Kunststoffverpackungen and ELIPSO, the French association for plastic packaging and flexible packaging. Plastic packaging makes the future possible Copyright: Messe Düsseldorf "Less unnecessary energy consumption, green energy, security of supply of materials, eco-design of packaging, recycled and bio-based materials, development of recycling channels and a clear European regulation for packaging waste – these are the challenges of our time." Gael Bouquet , Managing Director ELIPSO Packaging industry shows attitude "The PackTheFuture Award is an important signal. It shows that the packaging industry is willing to take responsibility and develop solutions that meet both the needs of consumers and the requirements of environmental and climate protection. The packaging presented here is proof that plastics, innovation and sustainability go hand in hand and that the transformation of the packaging industry is already in full swing." Mara Hancker , Managing Director IK Both associations, Elipso and the IK, are convinced that there can be no ecological and energy turnaround without plastic packaging. "Plastic packaging is becoming lighter and lighter, contains recycled or bio-based materials, is itself recyclable and is constantly evolving thanks to the genuine know-how of our industry," explains Gael Bouquet. The winners of the PackTheFuture Award 2023 Category: Design for Recycling Copyright: adapa DACH GmbH "VACUshrink(re) MEX 55" from adapa DACH GmbH (Germany) The certified recyclable PE-based shrink bag VACUshrink(re) MEX 55 with EVOH high barrier is suitable for fresh and processed meat or undercooked and matured cheese. It contains no PA layers or PVdC barrier and is produced without cross-linking. By using a three-dimensionally stretched polyolefin structure with a film thickness of only 55 μm, adapa has succeeded in meeting the high demands for product protection and processability and combining these with greater sustainability: VACUshrink(re) MEX 55 scores with excellent mechanical properties: it can be easily processed on standard packaging equipment and has good puncture resistance. The shrink bag is fully recyclable The VACUshrink(re) MEX 55 was awarded the World Star Award 2023 in the category Packaging Materials and Components. Copyright: ALBEA Services SAS "EcoFusion PCR Max Thin-Wall" from ALBEA Services SAS (France) EcoFusion Top with Thin-Wall & PCR max is the lightest and most recyclable solution that meets all criteria for greater recyclability by combining the 3 Rs: Reduction, Recycled Content, Recyclability. To have a major impact on weight reduction, ALBEA has removed one component by fusing the head and cap, clearly demonstrating its efforts to reduce plastic consumption. EcoFusion Top alone weighs only 2.4 g compared to 12 g for the standard head with cap. In addition, the solution is made of 100% PE, making the tube suitable for recycling in HDPE streams. It contains 41 % recycled plastics (PCR Max with 70 % r-HDPE in the jacket). Apart from the design, this innovation is a breakthrough in the production process as it can be used in both extruded and laminated tubes. Copyright: The Body Shop/Aptar Beauty Shower gel range from The Body Shop with the recyclable "Future" pump from Aptar Beauty The Future pump is made entirely from a single material, PE, thanks to a patented technology that includes an all-plastic motor. It is therefore fully recyclable when combined with a PE or PET bottle, as sourced from The Body Shop. Another unique feature is an integrated lockable ring and 360° actuator that minimises the risk of breakage and eliminates the need for a disposable safety ring, making the Amazon pump ISTA-6 compliant. The Future Pump is thus a groundbreaking innovation in the beauty industry in terms of technical innovation, sustainability and consumer experience. The Body Shop's new packaging was launched in Europe in Q4 2022 with a customised pump in the green colour and logo on the top. "LT clear 515R" from LEYGATECH (France) The special feature of the LT 515 laminating film is its structure: EVOH/PE/EVOH. The EVOH layers are on the outside and enclose the polyethylene layer (PE). This film offers high temperature resistance, very good optical properties and a gas barrier. When complexed with another PE film, it allows converters to produce bags or lids from a single PE material. LT 515 is suitable for printing, coating or sealing. This solution is ideal for replacing complex PET/PE or OPP packaging. The film is part of LEYGATECH's circular economy range as it can be 100% recycled in the existing recycling stream. "CPPeel®" from Profol GmbH (Germany) Profol's new CPPeel® lidding film is key to the production of mono-material polypropylene packaging. CPPeel® is ideal for yoghurt pots, dairy product packaging, salad trays, portion packs or cosmetic containers. The CO2 footprint of CPPeel® is 4 times better than existing aluminium packaging. The new CPPeel® lidding film in transparent or white, together with PP cups and trays, forms the basis for a sustainable mono-material packaging that is 100% recyclable. This mono-material packaging design makes it easy to sort and recycle packaging. Special price Copyright: Sidel "1SKIN" from Sidel (France) 1SKIN™ is a stylish, minimalist 1-litre container for sensitive beverages that enables distinctive, sustainable brand positioning. It is designed to support the Circular Economy, achieve a low carbon footprint and open the doors to new, digital communication opportunities. 1SKIN™ features an eco-friendly swing-top closure and ensures high performance while extending product shelf life with just the right weight of 100% recycled PET. By replacing virgin PET with recycled PET, 1SKIN™ also reduces CO2 emissions by five times. Its no-label design reduces the weight of the primary packaging by 10%. With a glass-like appearance and surface, 1SKIN™ offers a high-quality, sustainable packaging with 10 times less CO2 emissions. The bottle provides access to more information thanks to a QR code on the lid. Special mention Copyright: PEKU Folien GmbH "PE drawstring bag" from PEKU Folien GmbH (Germany) PEKU Folien has developed the functional and widely used drawstring bag into a one-material product. The previous cotton cord has been replaced by an LDPE cord. The function remains the same with the PE cord: the simple closing, opening and fastening of the bag with the cord enables safe multiple use and keeps the packaged product hygienically clean. Bag and cord are made of one material and are therefore 100% recyclable after use. To ensure that the PE cord does not weld itself to the PE bag during the sealing processes, but can move freely in the bag seam as before, an optimal solution was developed after numerous tests and with a lot of film expertise. During disposal, the cord no longer has to be separated from the bag, but can be fed into the cycle as a complete product for recycling. Category: Design for product protection Copyright: Bischof+Klein SE & Co KG "TacFlex® 900" from Bischof+Klein SE & Co KG (Germany) The TacFlex® 900 series was introduced to the market last year. The addition of grades with recycled content necessitated the development of a suitable material flow, as conventional sources of regranulate do not meet the high requirements of surface protection films. This has now been achieved with Cirlen regranulate production at Bischof+Klein; the first films have been extruded in the Innolab and industrial production is imminent. The innovation improves the protection of the contents from filling to the end consumer. TacFlex® 900 is adhesive-free and thus completely recyclable, yet still strong, resource-saving, climate-friendly - and now also available with a 30% recycled content. Copyright: Sleever "LDPET White Barrier" from Sleever (France) Sleever will launch the first low-density sleeve label compatible with closed-loop PET recycling in 2023: LDPET® White Barrier. This innovation is aimed at marketers of liquid and solid foods (beverages and dairy products). In addition, Sleever offers the energy-saving equipment "Combisteam LDPET WB" thanks to its system range. Combisteam is modular, designed for high speeds and enables energy consumption to be reduced by up to 50 % without compromising on performance. The light barrier function of the LDPET White Barrier product enables longer shelf life and protection of vitamins, colours and flavours. Category: Design for consumer benefit/user-friendliness Copyright: Bischof+Klein SE & Co KG "U-Pack® FFS" from Bischof+Klein SE & Co KG (Germany) The U-Pack® FFS is a combination of the well-known standard FFS film and the U-Pack®. The U-Pack® FFS represents an upgrade of the FFS film: Stabilo seams, a resealing system and a high-quality carrying handle are now possible. The aim was to offer the end customer features that are standard in single-bag filling but have been a problem in high-speed filling on reels. With the reseal feature, the package can be closed after product removal and allows for longer shelf life. Easy-opening without the use of a knife is also possible. The carrying handle offers easy handling for large bags. In addition, the U-Pack® FFS can be filled at the same machine speed as standard FFS. There is no need to invest in additional equipment in the line. This also eliminates the disadvantage that these sometimes reduce the filling speed by up to 40 %. Copyright: Bericap Holding GmbH "easyconnect" transfer system from Bericap Holding GmbH (Germany) The closure, jointly developed and manufactured by Bericap, is part of the closed transfer system easyconnect, which makes the filling of liquid crop protection products more efficient and safer. Used with the coupler, the system saves time and effort when filling the syringe and reduces the user's risk of contamination by a factor of >50 compared to the previous filling method. For emptying, the coupler opens the easyconnect lid and closes it again leak-proof by means of an innovative mechanism. Category: Design for reuse Copyright: Knauf Industries "BEAM® packaging" from Knauf Industries This is the packaging for packing and protecting the BEAM® robot from Awabot, the pioneering integrative telepresence company in France. The packaging has been redesigned and made from a single material, expanded polypropylene (EPP). Compared to the cardboard solution, the weight is 34 % less (i.e. 2.6 kg resource saving per robot), and even 80 % less for the flightcase solution. The packaging consists of 25 % recycled material and is 100 % recyclable at the end of its life. More around Packaging

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