Expertise Meets Purpose in Next-Gen Extrusion at K 2025 Preview

Performance. Perfected. For you – with this slogan, KraussMaffei will be presenting at K 2025 (Düsseldorf, October 8th – 16th) how leading-edge technologies and a top customer orientation provide measurable added value. The focus of extrusion technology is on solutions for more efficient and future-oriented plastics processing – from large-scale industrial polymer production to pipe and profile extrusion and to efficient recycling processes. The trade fair appearance will be supplemented by digital innovations to enable smart, low-operator production.

The development roadmap for the coming years is clearly defined: “We are working specifically on new developments to continuously increase customer benefits, actively maintaining our products and resolutely driving forward the digitalization and automation of our products.” This is how KraussMaffei Extrusion is creating the foundation for sustainability, economic success and technological progress. “And we are making this tangible for visitors at K 2025 in Düsseldorf,” says Ralf Benack.

Future market petrochemicals: New processing extruder for raw polymer production

One of the latest significant advancements is the latest generation of ZE Petrochemical (ZE-PC) compounding extruders, specifically designed for the high requirements of large-volume polymer manufacturing. Drawn from the successful BluePower technology, the co-rotating twin-screw extruders – with screw diameters up to 400 mm – integrate energy efficiency with superior processing quality.

“Thanks to a D/d ratio of 1.65, torque densities of up to 16 Nm/cm³, and variable-speed drives, the machines can run at lower screw speeds without compromising throughput. This lowers the specific drive power and reduces the melt temperatures, which lowers the risk of degradation,” explains Dr. Thomas Unger, Vice President Technologies at KraussMaffei Extrusion. At the same time, the larger diameter ratio ensures significantly more effective degassing. “This allows us to offer our customers an economical, reliable and material-friendly solution,” he adds.

“Performance. Perfected. For you. reflects our commitment to delivering advanced extrusion solutions – technically refined, highly efficient, and consistently geared to the requirements of our customers, Our strength lies in the combination of highly developed mechanical engineering and deep process know-how – all from a single source, reliably delivered worldwide.” –  Ralf Benack, Managing Director of KraussMaffei Extrusion GmbH

Increased output, reduced investment – cost-optimized recycling processes

Bottle-to-bottle PET recycling to material preparation for chemical processes – as a circular economy innovation driver, KraussMaffei Extrusion provides trailblazing solutions for any type of recycling. In the field of PET recycling, KraussMaffei Extrusion is showing a high-performance twin-screw system from the BluePower series for throughputs of up to 12 tons per hour. The technology answers the growing need for greater output and more energy- and cost-effective processing. It is up to 20% lower in energy consumption compared to traditional twin-screw systems. They are compatible with standard SSP units and yield food-grade rPET.

In chemical recycling, KraussMaffei Extrusion is focusing on key technologies: high-performance extruders for processing material streams – for example, to produce pyrolysis oils – efficiently implement crucial process steps such as dewatering, degassing and the removal of impurities. Pressures of up to 200 bar and the retractable UltraGlide system with easy-to-maintain screws enable customized solutions for demanding recycling applications.

KraussMaffei Extrusion has also refined its EdelweissTechnology for processing recyclates more efficiently – even with fluctuating material properties. The focus is clearly on process optimization and cost efficiency. The twin-screw extruder covers all process steps: degassing, filtering and compounding. “This integrated setup can lower investment costs by up to 25%,” says Dr. Thomas Unger.

More efficient research, more economical production: ZE BluePower in a new design

Whether for research or daily production – the new generation of the ZE BluePower twin-screw extruders offers clear advantages. The new ZE 28 BluePower scores with improved operation, greater energy efficiency and digital networking via ppC (pioneer processControl). The larger ZE 42-80 series has also been comprehensively redesigned – with a focus on simple maintenance, digital interfaces and an optimized modular system. “For our customers, this means a better price-performance ratio and shorter delivery times – real advantages in day-to-day operations,” says Dr. Thomas Unger.

New multilayer pipe head processes up to 100% recyclate

With its newly developed PVC multilayer pipehead, KraussMaffei Extrusion is demonstrating how pipe and profile extrusion can be made more sustainable and future-proof. The system processes up to 100% recycled PVC – even with varying material quality. The layer configuration can be flexibly adjusted depending on the application. A newly designed flow system prevents spiderlines and ensures consistent product quality with optimal material usage.

Digital transformation: rethinking machine control

With the new ppC (pioneer processControl) control system, KraussMaffei is bringing greater clarity and efficiency to extrusion processes. Instead of complex operating logic, ppC relies on intuitive processes, clearly structured user guidance and a unified user interface. This shortens the learning curve, reduces the amount of training required and makes everyday production easier. Its modular design enables use across all extrusion tasks – from Flat & Foam to Pipe & Profile through to Compounding and Recycling.

Integration into existing systems is also easy: interfaces for connecting to third-party devices such as metering devices, measuring systems and higher-level systems such as MES or DCS enable the central operation and monitoring of entire systems. This ensures greater transparency and process reliability.

Looking ahead: on the way to production without operators

In view of growing staff shortages, KraussMaffei Extrusion is developing digital tools for production without operators (PWO). Start-up workflows, AI-supported assistants and HMI solutions for mobile use make it easier to monitor entire lines – with fewer personnel. The first systems are already running unmanned at weekends – a milestone towards lights-out manufacturing.

Tailor-made Lifetime Service for maximum system efficiency

With its Lifetime Service, KraussMaffei Extrusion offers a comprehensive service concept that goes far beyond routine maintenance. “From commissioning and targeted modernization and data-based services, we support our customers throughout the entire life cycle of the system – reliably, proactively and with personalized solutions,” says Ralf Benack. Whether it’s spare parts, remote support, training, or digital condition monitoring, the goal is always the same: maximum plant availability, consistent product quality, and a sustainable boost in overall efficiency.

Performance. Perfected. For you.

KraussMaffei Extrusion’s presence at K 2025 underlines its commitment to combining innovative technologies, sustainable solutions and maximum cost-effectiveness in perfectly coordinated system solutions – individually tailored to customer requirements along the entire polymer processing value chain.

www.kraussmaffei.com

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Sustainable and Smart Extrusion Technologies Are the Stars of the K 2025 Stage

As the world plastics industry looks ahead to one of the most significant trade shows in the world—K 2025 in Düsseldorf—battenfeld-cincinnati stands out as a leader, emphasizing its dedication to ecological responsibility, technological innovation, and optimized production. With its thematic call to action “Think Green, Act Smart, Extrude Sustainably,” the company is not just attending—it’s leading the charge. As a global market leader for extrusion machines, battenfeld-cincinnati will illustrate how the values of sustainability, digitalisation, and industrial performance are not only compatible but also reinforcing each other. This year’s K 2025 is more than an exhibition—it’s a declaration that the strength of plastics is being re-defined for a more sustainable future.

“We are demonstrating that green, smart, and responsible are specific development guidelines for us. The combination of economic efficiency, high flexibility, and active sustainability makes battenfeld-cincinnati a reliable partner for future challenges. We look forward to discussing these topics in person with our customers at K and developing them further.”

The plastics market is being revolutionized by customers and regulators alike, who are demanding smarter operations, improved resource efficiency, and closed-loop solutions. Plastics processors today have to function in a fast-pressure market where innovation has to be a solution for live problems: energy consumption has to decline, recycled products have to be economical at volume, automation has to be wise, and product has to remain competitively priced. To meet these increasing needs, battenfeld-cincinnati is launching an extensive range of innovative extrusion technologies, converting vision into real-world, sustainable engineering.

Center of attention at the firm’s stand is the latest BC 120-40 DVT single-screw extruder, an innovation that sets a first by being the first of its kind to come with Dual Vent Technology. This technology advancement brings with it a two-stage melt degassing system tailored to deal with tough and dirty recycled materials without compromising on better product quality. This degassing process eliminates volatiles and water more effectively, with the capability to accept high levels of recyclate content in the feedstock without compromising the integrity of the end product. Maybe most impressive is that all this is done with lower energy consumption, lesser thermal loads, and less waste—characteristics of a system fully in line with sustainable objectives.

This new extruder wasn’t created in isolation. It’s the product of global collaboration across battenfeld-cincinnati’s R&D and engineering divisions. Its development reflects a core philosophy of leveraging internal synergies, integrating proprietary software, thermal management systems, and mechanical innovations into a unified machine platform. More than just a new piece of hardware, the BC 120-40 DVT serves as proof of concept that future-ready extrusion systems can be high-performing and environmentally sound at the same time.

In pipe extrusion, the company also debuts another significant innovation: Intelligent Operating Adjustment (IOA). This automated centering system of ball-joints significantly decreases operator intervention in pipe production, optimizing the use of materials and enhancing accuracy. IOA allows the extrusion line to automatically maintain optimal positioning, with the result that the pipe is always centered—something usually requiring operator expertise and constant adjustment. With reduced material required for the corrections and less rejects, the system increases productivity as well as sustainability. It is also a classic case of Industry 4.0 in practice—autonomous, smart, and highly integrated into the digital world of manufacturing.

In addition to this, battenfeld-cincinnati introduces a new degree of flexibility with its piggyback coextrusion solution, a space-saving line integrating the twinEX 78 and conEX NG 65 extruders. This innovative technology enables the simultaneous processing of virgin PVC, recyclates, and special compounds with high output and consistent quality. The design is suited to manufacturers that face varying production requirements, allowing them to change product types rapidly or blend materials for new products. The NG series extruders also cement their green credentials through the use of low-energy screw design, accurate thermal zoning, and the capability to process heat-sensitive materials—all with the ability to produce scalable outputs adequate for commercial-level manufacturing.

For producers of sheets and films, the upgraded multiTOUCH-X roll stack with Axis-Crossing Technology is making waves. Designed for extremely thin films—such as polypropylene below 200 microns or PET below 150 microns—the system eliminates the need for vacuum boxes. This not only reduces energy requirements but also shortens startup times and improves safety. The result is high-speed production with minimal scrap and outstanding film quality. In terms of innovation, it’s a leap that supports lightweight packaging and recyclable film applications, which are gaining traction as both consumers and regulators push for reduced environmental impact.

To complement this, the new solEX NG 105 extruder is being launched, offering throughput levels of up to 2,100 kilograms per hour while maintaining lower melt temperatures. What sets this extruder apart is its closed-loop cooling circuit, developed entirely in-house. Unlike conventional systems, this cooling loop operates independently of the main water supply, offering corrosion protection, thermal stability, and extended longevity of key extruder components. For manufacturers, this translates to better machine uptime, fewer maintenance disruptions, and significantly lower operational costs.

In downstream processing, the company is showcasing its next-generation pullStream B63-1000 WS belt haul-off, designed with World Solution Design principles. Its ergonomic structure prioritizes user-friendly operation, offering tool-free maintenance access, integrated belt alignment, and a 10-inch touchscreen interface for intuitive control. Even at high line speeds of up to 300 meters per minute, the system ensures consistent pipe quality and seamless integration with other line components. It exemplifies how operator comfort, digital control, and production efficiency can coexist to create superior manufacturing environments.

One of the more forward-looking tools on display is the Spider NG tooling system, a modular setup tailored for the evolving demands of PVC pipe manufacturing. Its design allows quick adaptation to changing requirements, enabling manufacturers to shift product formats, layer configurations, or input material compositions without needing entirely new die heads. This level of adaptability is especially vital in today’s regulatory climate, where producers must be ready to meet new environmental standards and shift toward higher use of recyclates or bio-based compounds.

That vision isn’t theoretical—it’s supported by a wide portfolio of machines and services designed for real-world implementation. battenfeld-cincinnati’s full range includes solutions for pipe, profile, thermoforming sheet, and packaging film extrusion. Their platforms—like solEX NG, conEX NG, uniEX, and others—are supported by process control innovations such as BCtouch UX, a unified control interface that brings user-friendly navigation, predictive maintenance, and OPC UA-ready data integration into every machine.

In fact, digitalization is a key enabler of their sustainability goals. With BCtouch UX, operators receive real-time feedback, automated diagnostics, and intelligent system suggestions—reducing downtime, material waste, and human error. Its connectivity to manufacturing execution systems (MES) and enterprise platforms also supports traceability, regulatory compliance, and lean manufacturing principles.

Globally, battenfeld-cincinnati serves customers with a distributed network of service centers and manufacturing sites. From Europe to North America to Asia, their regional hubs provide commissioning, remote diagnostics, preventive maintenance, and training tailored to local market needs. Their “World Solution” standard ensures that equipment specifications meet the highest international benchmarks while allowing for customization to meet local processing norms or climate conditions.

What truly distinguishes battenfeld-cincinnati at K 2025 is their ability to turn abstract ideals—like circular economy, energy efficiency, and digitalization—into tangible, measurable, and profitable realities for processors. From their dual-vent extruders that make high-recyclate content feasible to automated centering systems that reduce waste, their portfolio is not just innovative but strategic. For converters, brand owners, and compounders alike, their systems offer a roadmap to future-proof manufacturing.

As the countdown to K 2025 continues, battenfeld-cincinnati is positioning itself not only as a provider of cutting-edge machinery but as a key architect of the plastics industry’s next era. It is a future defined not just by performance, but by purpose. One where plastics—so long seen as a sustainability challenge—are being reimagined as part of the solution. A future where thinking green, acting smart, and extruding sustainably are not marketing phrases but operational realities.

https://www.battenfeld-cincinnati.com/

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Visionary Solutions for a Greener Planet Unfold at K 2025 Preview

As K 2025 draws near, the world’s leading trade fair for plastics and rubber is once more attracting innovators, industry players, and sustainability champions. Among the highlights from the returning players is Röhm GmbH, the stalwart of the plastic industry and a perennial exhibitor at K since its launch in 1952. This time around, the spotlight is on Röhm’s PLEXIGLAS molding compounds with the irresistible theme, “PLEXIGLAS makes your design shine.”. Day by day.” The brand’s polymethyl methacrylate (PMMA) chemicals will be highlighted in various superior-quality, eco-friendly product offerings that capture the smartness, variability, and ecological compatibility that today’s consumers and industries increasingly require.

PLEXIGLAS is world famous for its optical transparency, UV stability, and durability. These features not only position it as the preferred material for aesthetic and functional product use but also for environmentally friendly solutions in major industries including automotive, electronics, architecture, and consumer goods. Röhm will demonstrate at K 2025 how PLEXIGLAS compounds support sustainable development objectives, support high-end design, and enhance product performance simultaneously. The brand’s ability to maintain its attractive appearance over time—gloss retention, clarity maintenance, and color depth preservation—guarantees that its products will last longer, reducing the need for replacement and waste production. For engineers and designers, PLEXIGLAS is more than simply a material; it’s a medium that transforms creative concepts into durable, sustainable realities.

Aligning with the master theme of K 2025, “Shaping the Circular Economy,” Röhm is highlighting PLEXIGLAS’s recyclability and sustainable life cycle. PMMA is perfectly positioned for circularity due to its chemical composition that enables efficient recycling, such as depolymerization to its initial monomer state. It is a distinctive benefit over other plastics, which tend to break down in recycling. Röhm is investing in this closed-loop strategy and creating sophisticated recycling technologies that allow for genuine circularity—to convert end-of-life PMMA products into virgin-quality material that is reusable in high-performance applications. At the trade fair, the company will highlight molding compounds that incorporate post-industrial recyclate, demonstrating that even highly engineered materials can be part of the solution to plastic waste.

This year’s exhibition will also introduce visitors to Röhm’s pioneering production technologies that align sustainability with industrial scalability. The business is introducing innovative production methods that lower emissions, use less energy, and boost the percentage of recycled materials in its goods. These developments benefit downstream firms who want to lessen their own carbon footprints because they not only improve process efficiency but also lessen the environmental impact of production. Röhm takes a comprehensive approach to sustainability, taking into account the source of raw materials, energy consumption, processing effectiveness, and end-of-life recyclability. In a time when resource responsibility and environmental compliance are major concerns for all companies, this holistic approach enhances their standing as a progressive supplier.

At Röhm’s stand, they will be treated to a photographic tour of everyday uses showcasing the performance, beauty, and sustainability of PLEXIGLAS. A major area of emphasis will be within the automotive industry, where PLEXIGLAS Hi-Gloss and LED-suited grades are utilized in tail lights, illuminated logos, and interior trim. These parts demand not only excellent clarity and esthetics, but also thermal stability, weather resistance, and processability for high-volume production. Röhm will also feature PMMA parts in e-mobility solutions, including lightweight glazing for windows, aerodynamic lighting shrouds, and lighted charging connections. These applications demonstrate the material’s role in reducing vehicle weight, energy consumption, and brand differentiation—all with recyclability.

In architecture and construction, PLEXIGLAS continues to be a material of choice for its transparency, formability, and resistance to UV degradation. At K 2025, they will present applications such as façade panels, acoustic barriers, and skylight domes that illustrate how PMMA can be integrated into modern building envelopes for both aesthetic and performance gains. Transparent and colored variants, textured or glossy finishes, and custom formulations enable architects to achieve creative visions while meeting energy efficiency and sustainability criteria. Similarly, in the consumer electronics space, PLEXIGLAS is used in high-gloss covers, backlit displays, and tactile interfaces. These components demand scratch resistance, durability, and visual precision, all of which PMMA provides.

Their presence at K 2025 is not only about showcasing materials—it is about setting new standards for what plastics can achieve in a circular economy. This includes the launch of new molding compounds that integrate recycled PMMA without compromising on mechanical or optical properties. These grades are suitable for a wide range of applications, from durable goods to interior components, offering customers a seamless path to improved sustainability credentials. Furthermore, the company is exploring bio-attributed PMMA made from renewable feedstocks, which reduces dependence on fossil-based inputs and supports carbon neutrality goals. By embedding circular economy principles into product development and manufacturing processes, there are making it easier for customers to transition to more sustainable production models.

Digitalization is also at the forefront of Röhm’s future plans. The firm is creating digital product passports and data-driven lifecycle monitoring tools that will enable OEMs and processors to track material provenance, determine environmental performance, and meet ESG (Environmental, Social, and Governance) reporting obligations. These developments do more than provide greater transparency; they also enable compliance with regulations as well as brand integrity in a more sustainability-oriented marketplace. In doing so, PLEXIGLAS is not just a physical material but an information-enabled solution for businesses looking to measure and enhance their environmental impact.

They are also working in collaboration with recyclers, policymakers, and industry groups to shape a more responsible plastics economy. This includes participation in global certification programs such as ISCC PLUS, which assures the sustainable sourcing and production of chemicals and polymers. Through joint ventures, pilot projects, and supply chain engagement, the company is accelerating the commercialization of circular PMMA solutions and contributing to broader industry transformation.

Visitors at Röhm’s booth in K 2025 can look forward to a comprehensive, immersive experience. Aside from product displays, there will be real-time demonstrations of material attributes, talks with technical specialists, and chances to navigate the entire life cycle of PLEXIGLAS through online portals. The booth itself is also sustainably planned, with recycled and reusable components to further solidify the values of the company. It is a physical representation of the brand’s slogan—design that shines daily—and its greater commitment to making a cleaner, more sustainable world possible through materials.

Röhm’s presence at K 2025 demonstrates the company’s ten-year commitment to sustainability, innovation, and excellence. PLEXIGLAS develops as a multifaceted, accountable, and performance-focused solution in the face of global environmental issues, resource constraints, and regulatory changes. Its benefits span decades, its applications cut across industries, and its circular potential shines bright in a world that is in dire need of both literal and symbolic clarity.

While the plastics world is racing toward a more sustainable tomorrow, Röhm is forging ahead with transparency, innovation, and purpose. At K 2025, it doesn’t merely exhibit products—it weaves a tapestry of transformation, one in which smart design, technical mastery, and environmental responsibility are balanced under one material vision. And in doing so, Röhm challenges the world to envision a tomorrow in which sustainability burns as brightly as design—each and every day.

www.roehm.com

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K 2025 Showcases How Smart and Circular Materials Are Transforming Industries

At K 2025 in Düsseldorf this October, Covestro will unveil a powerful narrative under the banner “The Material Effect,” revealing how advanced material science can solve some of today’s most pressing global challenges. As the world’s premier trade fair for plastics and rubber, K marks a pivotal moment for the industry—and Covestro is seizing it to spotlight over 20 innovation stories that embody its vision of becoming fully circular. This vision has gained renewed urgency amid overlapping crises—from climate disruption and energy volatility to geopolitical and supply chain tensions—reminding us that resilience now demands adaptability, innovation, and sustainability more than ever.

“The world seems to have gone off track, and the chemical industry is feeling the full force of the current multiple crises,” he warned. Yet he also highlighted a hopeful direction: “The future will be ever greener and smarter. At Covestro, we are paving the way for that… with our recyclable, climate-neutral high-performance plastics—whether in e-mobility and autonomous driving, efficient buildings, or digitalization.”

At booth A75 in Hall 6, visitors will witness how Covestro is mobilizing its expertise in sustainable future, automotive, electronics, healthcare, and sports & leisure. Among the standout exhibits is the SUE “People Mover”, a driverless electric shuttle by UE | STUDIOS built with polycarbonate glazing, lidars, and mono-material components like Arfinio and TPU. This concept vehicle highlights how lightweight, recyclable polymers with exceptional durability and design freedom can transform urban transportation.

Digital innovation also takes center stage with IMAGIO, a digital sampling tool that creates realistic material twins for product visualization in early design stages—eliminating the need for physical prototypes and accelerating time-to-market. This tool exemplifies their push toward digitized material development, aligning with broader digital transformation trends across industries.

Behind the exhibit—and behind “The Material Effect”—is Covestro’s deep-rooted strategy for circularity and climate neutrality. The company aims to achieve full circularity by using alternative raw materials, green energy, and advanced recycling technologies. Internally, Covestro targets operational climate neutrality (Scope 1 and 2) by 2035, and ambitions extend to complete value-chain climate neutrality (Scope 1–3) by 2050. They are achieving this through eleven Power Purchase Agreements, supplying about 16 percent of their global energy use with renewables.

A key strategy is the increasing use of alternative raw materials—including biomass, post-consumer waste, CO₂ sources, and green hydrogen—through mass-balance procurement certified by ISCC PLUS. This allows fossil and renewable feedstocks to be processed together while attributing green content to finished products. Covestro now applies mass balance at over 20 global sites, including prominent plants in Leverkusen, Krefeld-Uerdingen, Dormagen, Baytown (US), Shanghai, and Changhua (Taiwan).

The company’s CQ label—short for Circular Intelligence—marks products with at least 25 percent alternative raw materials. Within CQ, additional sub-labels define sourcing and production methods: RE for renewable-based polycarbonates, RP for chemically recycled post-consumer polycarbonate via mass-balance, and R for mechanically recycled content. Notable early CQ-certified products include climate-neutral polycarbonate from Krefeld-Uerdingen and EIDesmodur CQ, a mass-balance MDI introduced in 2022.

“The Material Effect’ enables our customers and partners to achieve more—in terms of sustainability, circularity, and performance.”

Covestro is also establishing innovative recycling technologies under the Evocycle CQ brand—chemically recycling polyurethane mattress foam into raw materials for new production. This pilot contributes to a broader “Circular Foam” collaboration involving 22 partners, with the goal of recycling one million tons of PU foam and saving 2.9 million tons of CO₂ annually by 2040.

Concrete examples of CQ applications span multiple sectors. In electronics, polycarbonate grades like Makrolon RP with up to 72 percent recycled share deliver virgin-quality transparency and durability while promoting circularity. At the same CES 2025 event that showcased IMAGIO, Covestro highlighted polycarbonate innovations, battery packaging resins, and electronics solutions—all underlining “Material Effect” themes of performance and sustainability.

In automotive and mobility, CQ polycarbonates are enabling low-carbon EV charging stations and lighting components, while sustainable coatings and adhesives—including bio-based clearcoats developed in collaboration with Audi and BASF—support decarbonization across the vehicle value chain.

The strategy presentation previewed at K also outlines Covestro’s directions: nearly 1 billion in circular economy capex over 10 years, an R&D investment shift where 80 percent of R&D spending targets UN SDG-related projects by 2025, and emission reductions goals of –30 percent for Scope 3 by 2035. These extend R&D into quantum computing, biotechnology, and electrochemistry to accelerate circular breakthroughs.

At K 2025, Their  innovation roadmap will be on full display—from advanced materials in health care and sports to building insulation, beverage packaging, and digital interfaces. Each of the 20+ innovation stories illustrates how “The Material Effect” can deliver measurable outcomes: lower carbon footprints, improved product lifecycles, and material-driven societal impact. Each story reinforces Covestro’s core message: materials are not merely enablers—they are tools for transformation.

Underlying this is the idea, championed by Jochen Hardt, Vice President and K 2025 project lead, that Covestro’s strength lies in combining material science, process engineering, and application know-how. “That unique combination… makes the decisive difference,” Hardt said. “ ‘The Material Effect’ enables our customers and partners to achieve more—in terms of sustainability, circularity, and performance.” At a moment when the chemical industry faces multiple pressures, Covestro stands firm: performance must be sustainable, and sustainability must perform.

Covestro’s presence at K 2025 is not simply a product showcase—it is a strategic manifesto. In person and through interactive exhibits, the company will demonstrate how the circular economy, digital acceleration, and climate neutrality are no longer distant goals but operational pathways available today. From cradle-to-gate, cradle-to-cradle, and digital twins to driverless e-shuttles, Covestro’s message at K will be clear: The Material Effect empowers industries—and societies—to build a resilient, net-zero future with the power of high-performance, circular plastics at its heart.

https://www.covestro.com/

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Revolutionizing Plastics: K Preview 2025 Sparks International Industry Insight

With over 70 journalists from 33 countries, 15 leading exhibitors, and three days of intensive dialogue, K‑Preview 2025 has officially launched the journey toward this October’s main event—K 2025 in Düsseldorf. More than a sneak peek, the preview delivered a compelling snapshot of the current pulse of the plastics and rubber industry: one that is increasingly sustainable, technologically advanced, globally interconnected, and forward-looking. As stakeholders from across the supply chain gathered for this exclusive prelude, it became evident that the industry isn’t just preparing for change—it’s leading it.

One of the hallmarks of K‑Preview 2025 is its rich offering of breakthrough technologies and innovations. Nothing more than conceptual demonstrations, the systems and equipment showcased were ready-for-market solutions designed to address the industry’s most daunting challenges. Whether state-of-the-art extrusion systems, cutting-edge recycling lines, or intelligent machines embedded with AI, the participants revealed a future where performance, sustainability, and economic efficiency come together. Live exhibits involved third-generation mechanical recycling facilities that can process post-consumer mixed plastics at high yields, ultra-thin but strong extrusion equipment making films, and digital twin platforms allowing producers to run simulations of production without the utilization of actual resources.

But K‑Preview isn’t just about machinery—it is also about mindset. Strategic dialogues take center stage as global leaders from material science, equipment manufacturing, brand ownership, and regulation gathered to discuss the transformations taking place in global markets. Topics ranged from the alignment of circular economy regulations across major economic regions to supply chain resilience amid global raw material fluctuations. Energy pricing, logistics bottlenecks, and the surge in demand for recycled content were all tackled head-on, creating a platform for collaboration and policy-driven innovation. Many of the discussions emphasized the urgency of shifting from traditional linear models to circular ones, not as an option, but as an imperative.

Crucially, K‑Preview facilitated deep and direct exchange between industry experts, decision-makers, and technical leaders. Unlike traditional expos dominated by formal presentations, this event fostered true engagement. Roundtables and open sessions allowed machine builders to interact with converters and recyclers in real time. Operators, engineers, and corporate sustainability officers shared success stories and failures—bridging gaps between theory and practice. Start-ups are given space to pitch novel materials and digital solutions to potential partners and investors, many of whom provided invaluable feedback on how to scale effectively.  This dynamic atmosphere of exchange and cross-sector collaboration that made K‑Preview more than just a trade show preview—it is a community in action.

The core themes of K‑Preview were also carefully selected to mirror the most critical issues shaping the industry: circular economy, digitalisation, and global competitiveness. Under the circular economy umbrella, several exhibitors demonstrated how reusability, recyclability, and sustainable design can be fully integrated into industrial-scale production. From mono-material packaging films optimized for mechanical recycling to equipment tailored for post-industrial waste reprocessing, the message was clear: circularity is no longer an aspiration—it’s an operating standard. Digitalisation, meanwhile, was presented not just as an efficiency tool, but as a critical enabler of sustainability. AI-driven process monitoring, smart predictive maintenance, and cloud-based traceability platforms are now at the core of many production systems. These technologies not only optimize yield but also ensure compliance with evolving regulatory requirements for transparency and environmental accountability.

Competitiveness—a major concern for global manufacturers dealing with inflation, labor shortages, and supply chain volatility are tackled through solutions that drive down energy use, reduce scrap rates, and enable modular, flexible production systems. For example, several companies showcased machinery platforms that can be adapted to various film structures or materials with minimal downtime, thus enhancing both cost-efficiency and operational agility. At the same time, workforce challenges were addressed through automation solutions and training tools that make high-tech operations accessible even to less-experienced workers. The ability to remain competitive in a fast-changing landscape was not treated as a function of scale or legacy but of adaptability and innovation.

All of this is a precursor to the main event—K 2025 in October—where the international plastics and rubber community will gather to set the agenda for the coming years. Judging by the energy and insights on display at the Preview, K 2025 promises to be a milestone event. Scheduled from October 8 to 15 in Düsseldorf, the show is expected to feature over 3,000 exhibitors across 18 halls and over 170,000 square meters of space. It will include dedicated areas for machinery and equipment, raw materials and auxiliaries, semi-finished products, and technical components. The “Plastics Shape the Future” special show will return with new installations exploring how polymers can help solve global challenges, from clean energy to medical innovation. The VDMA’s “Power of Plastics” platform will spotlight the sector’s contribution to sustainable development through technology.

Unique zones like “Rubberstreet,” the “Science Campus,” and the “Start-Up Zone” will highlight emerging trends and foster innovation. The “Young Talents Lounge” and “Women in Plastics” programs will promote diversity and education, ensuring that the next generation is ready to lead with purpose. Sustainability, circular economy frameworks, and digital transformation will remain dominant themes, not just in exhibits but also in forums and symposia featuring global thought leaders.

The value of K‑Preview as a strategic accelerator cannot be overemphasized. By offering feasible solutions several months prior to the formal fair, it enables firms to seal deals, make purchasing plans, and coordinate R&D investments in time for October. With tightening environmental policies and heightened consumer consciousness, being early in the innovation curve presents a concrete competitive edge. In addition, the Preview enables exhibitors to receive feedback and tighten their exhibits so that they are most effective when the world comes together at K 2025.

According to several participants, the Preview served as a bellwether for industry readiness. A packaging engineer from a major FMCG brand remarked that the systems shown at the event finally allow brands to meet recyclability requirements without sacrificing shelf life or barrier performance. Another attendee, the CEO of a recycling firm, noted that the Preview validated his company’s direction toward chemical recycling collaboration, having met three potential partners at the event. These testimonials underscore the real-world impact of the Preview—beyond the walls of the venue and into supply chains, product roadmaps, and business models.

Ultimately, K‑Preview 2025 did more than set the tone for K 2025—it redefined it. It demonstrated that the plastics and rubber industry is not only capable of sustainable transformation but already well underway. With technologies now in place to support full-scale circularity, and a shift in global mindset toward long-term resilience, October’s main event will be a defining moment. The countdown to K 2025 has officially begun, and if the Preview is any indication, the industry is prepared to not just meet the future—but to lead it. From digital innovation and material science to global cooperation and regulatory alignment, the themes echoed in Düsseldorf will shape the policies, products, and possibilities of tomorrow. Stay tuned—the revolution has already begun.

https://www.k-online.com/

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Innovative Chemical Recycling Research at Utrecht University Powered by Twin-Screw Extruder

A Coperion STS 25 Mc11 twin screw extruder has been selected by the University of Utrecht for a study on chemical plastics recycling. The mechanical-chemical conversion of mixed plastic trash employing catalysts will be thoroughly investigated by a research team led by Assistant Professor Dr. Ina Vollmer. The Coperion STS twin screw extruder will play a key role in this exciting and mostly uncharted field because of its intense mixing effect and effective energy intake.

At the K trade show (8-15 October 2025, Dusseldorf, Germany) Coperion, together with Herbold Meckesheim, will present their entire repertoire of technology for plastics recycling at Booth 9B34 in Hall 9 as well as in the Open Area in pavilion FGCE07.

Efficient conversion of plastic waste using catalysts

In addition to established methods for recycling mechanical plastics, Coperion also has chemical plastics recycling operations. By repurposing plastic trash into premium raw materials, this technology may enable limitless recycling. The procedure is currently energy-intensive and does not always produce high-quality goods. Catalyst use may be crucial to the ongoing enhancement of process effectiveness and final product quality.

The University of Utrecht’s research project is dedicated to precisely this challenge. The STS 25 Mc¹¹ twin screw extruder, being installed there to carry out the experiments, processes waste plastic, shredded or compacted, with two co-rotating screws in a closed process section. Together, intensive dispersion and high shear introduce a great deal of mechanical energy into the material. The plastic is energy-efficiently melted – an advantage that is particularly important in chemical recycling. Moreover, the extruder achieves a very high mixing effect with its twin screws. The catalysts being implemented in this research project are distributed absolutely homogeneously throughout the plastic melt and can fully develop their intended effect.

In conventional pyrolytic processes, the hot plastic melt is prepared within the twin screw extruder for the next step in chemical processing: pyrolysis. There, in an oxygen-free environment, the plastic is broken down to its chemical building blocks. The temperature of the pyrolysis can be lowered thanks to the efficient use of catalysts, as Vollmer’s team has shown in preliminary work.

Said Dr. Ina Vollmer regarding her research assignment: “Using the extruder, we can achieve an efficient use of the catalyst. Still, our vision is to allow pyrolysis to take place even in the extruder. We can achieve this by exploiting the mechanical-chemical reaction that occurs within the twin screw extruder, and specifically convert the polymer at lower temperatures than have previously been necessary for pyrolysis. Mixing with high shear in the extruder has a very positive effect on the use of catalysts. We are convinced that we can direct the chemical recycling process more precisely using lower temperatures, and this will lead to purer products while at the same time having the potential to revolutionize the chemical plastics recycling process sequence and save energy. “

Should the use of catalysts in the chemical recycling process prove its worth, the results of this research will easily be transferable to larger throughput ranges.

“Following Dr. Ina Vollmer’s scientific approach, we will glean systematically researched results and draw conclusions for chemical plastics recycling from which we can all profit – recyclers and processors as well as end users,” noted Leonid Liber, Sales Engineer at Coperion. “We are proud that our STS twin screw extruder is part of this promising research project, and we wish Dr. Ina Vollmer much success. We look forward to continued collaboration.”

www.coperion.com

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