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Sika and Sulzer Lead the Way in Circular Construction Solutions

Sika and Sulzer Lead the Way in Circular Construction Solutions

Sika and Sulzer have signed a memorandum of understanding to establish a joint venture to advance plastics recycling in the construction industry. The aim is to combine the strengths of both companies: Sika’s extensive expertise in polymer applications and high-performance building materials and Sulzer’s leading process knowledge in chemical recycling. The joint venture, based in the Zurich area, will be founded as an independent company, with each partner holding a 50 percent stake. Operational activities will commence in the second half of 2025 with pilot projects in Germany, Austria and Switzerland. 

Approximately two million tons of plastic waste are generated in the European construction industry alone each year. Currently, recycling these complex materials is highly fragmented, technically demanding, and often inefficient. As a result, the majority of construction plastics are disposed by the end of their lifecycle, since existing mechanical recycling methods produce low-quality materials that are not suitable for reuse.

PARTNERING FOR SUSTAINABLE TRANSFORMATION OF THE CONSTRUCTION INDUSTRY
With this joint venture, Sika and Sulzer are developing a system for the collection, processing and reuse of construction plastics using mechanical and chemical processes.

Ivo Schädler, Head of Construction Sika: “This joint venture represents a significant milestone on our path toward greater sustainability and circularity in the construction industry. By converting waste into high-quality raw materials, the project helps reduce Scope 3 CO₂ emissions. At the same time, it supports companies in meeting increasing ESG standards and unlocking new value creation streams. Together, we are making a decisive contribution to the sustainable transformation of the construction industry, and thus to the future viability of the sector and our customers.”

Michael Schüepp, Head of Ventures Sulzer: “Sulzer technologies are at the heart of critical infrastructures and processes. Our solutions enable industries around the world to reduce emissions, reuse resources and recycle materials. Global developments show that our products, services and technologies are more relevant than ever. The combination of Sulzer’s and Sika’s technologies is now paving the way for the construction industry to achieve a functioning circular economy and an even more sustainable future. We are supporting an important industry on its journey toward a more cost-effective, efficient, and low-emission future.”

SYSTEMATIC RECYCLING OF CONSTRUCTION PLASTICS
The joint venture between Sika and Sulzer will close gaps in the value chain of the construction industry, and offer customers a comprehensive, cost-efficient service package. The offering will be complemented by local partners, such as logistics and recycling companies, which will be integrated into specific process steps. Recycled materials will thus be reincorporated into the manufacturing process.

https://www.sika.com/

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Signaling Eco-Consciousness with Plastic Colors, Finishes, and Materials

Signaling Eco-Consciousness with Plastic Colors, Finishes, and Materials

It is contradictory to use sustainable materials in product design. The question of where the sustainability story goes and how to communicate this amazing accomplishment arises when a less sustainable material is replaced with a more sustainable one and the new, more responsible version is so well done that it is visually identical to the original, less responsible version.

It is challenging to explain sustainability if the recycled, bio-based, low-carbon, or other environmentally friendly material you use looks exactly like the original plastic. There is no difference in appearance. The paradox of what we designers do is that the sustainability narrative itself frequently gets lost in the process of trying to be sustainable. Or does it? This subject is significant because the environmental aspect is given a lot of attention and is incorporated into the product story. By product, I mean anything from consumer electronics and recreational goods to household appliances and automobile interiors.

A large part of our work as designers is to reproduce our existing knowledge of common plastics and processes, but now we need to think about it responsibly and sustainably. For example, instead of electroplating plastics to create glossy premium finishes, we could instead use a recyclable process where the end result is very similar, if not visually identical, to the original. But do we simply want to replicate what we’ve always done (metallized plastics, glossy finishes) in a more sustainable way? Or do we actually want to do things differently, capture consumers’ imaginations, and excite them about a new approach? From a purely environmental perspective, a progressive aesthetic is less of a concern as long as everything is achieved in a more responsible way. But aren’t we missing a huge opportunity to do something truly different? Shouldn’t we be challenging expectations of good and desirable CMF (color, materials, and finishes)?

We’ve long accepted that materials like wood and metal have their own natural imperfections—knotholes in the wood, patina on brass or copper—and we even celebrate them as signs of authenticity, age, and beauty. Why don’t we do the same with injection-molded plastics?

Some pioneering brands are beginning to redefine the aesthetics of plastic. The Microsoft Xbox Remix Special Edition controller is a perfect example. Made from recycled plastic, it features subtle swirls, flow lines, and color variations on its surface—visible traces of the recycled content. Instead of covering up these “imperfections,” Microsoft has chosen to reveal them, making each controller visibly unique.

The Steelcase Perch stool takes this a step further. Made from hard-to-recycle plastics derived from e-waste, it exhibits numerous color irregularities and “ghost lines” created by the irregular melting behavior of recycled material. Instead of trying to improve the quality of the recycled plastic, Steelcase has embraced the imperfect surface—and even gone a step further by donating the “most irregular-looking” Perch stools, created during color transitions in production, to social innovation partners. They have portrayed this unpredictable aesthetic as a reflection of the complexity and change in the real world.

These examples point to a new possibility: to change the way we define beauty in plastic and to develop an aesthetic language in which the traces of manufacturing processes and raw materials do not remain hidden but become a sign of value and honesty.

The challenge is even greater for higher-end products, where traditional notions of luxury play a crucial role. There is often a strong desire to maintain familiar, high-end aesthetics, such as metallic finishes, which can complicate the introduction of new, visibly sustainable materials.

In addition to finding sustainable solutions for established materials and finishes like chrome, should we also explore other sustainable processes to characterize a new kind of luxury? Should sustainability actually help consumers change their understanding of luxury, rather than simply replicate their current one?

Some forward-thinking brands are already demonstrating how this transformation can be achieved. Panasonic, for example, has developed Nagori—a plastic material made from minerals left over from water treatment. Its layered, gem-like aesthetic offers a unique, sophisticated look that easily rivals the most luxurious conventional materials used for accents and details.

Similarly, unidirectional polypropylene (PP) fibers, commonly used in structural composites, lend a new visual language to non-material plastics. Their linear texture lends them a distinctive, high-end aesthetic that could be considered a modern luxury feature—a feature built on material innovation and 100 percent recyclability.

The problem is: common materials like plastics remain highly desirable. They are produced immaculately, pure, and flawlessly, instantly conveying a sense of luxury. This is the result of over 70 years of designers learning how to use plastics, metals, and new finishes. Perfection is still the norm. This is why virgin plastics and other materials have captivated us so much; a real shift in consciousness is needed to break away from the steady supply of predictable, high-quality, and optimized new goods to which we have become so accustomed.

One of the big trends in sustainable materials in recent years has been the speckled aesthetic. Whether made from natural fibers or inorganic filler waste, these effects steer the material story in a better direction. They not only celebrate the recycled or bio-based origins of the material but also create a unique, unrepeatable aesthetic that gives each product a unique fingerprint connected to its sustainability story.

Several brands, including major players in the automotive industry, have begun to adopt this new aesthetic on a large scale, working closely with material suppliers to develop innovative recycled qualities that showcase sustainability. One notable example is the Volvo EX30, which features speckled door panels and upholstery made from recycled materials. These striking textures have become a defining element of the vehicle’s interior design and have earned the EX30 several awards, including the prestigious 2024 Red Dot “Best of the Best” award.

Similarly, in collaboration with LyondellBasell, Dacia has introduced speckled plastic components for its vehicle interiors that incorporate post-consumer recycled materials. These finishes lend cars a sustainability-focused aesthetic and highlight the material’s recycled origin—a deliberate departure from the industry’s long-standing pursuit of flawless, uniform surfaces.

Interestingly, many consumers seem to be open to this change. Enthusiasm for products that visibly signal a shift away from environmentally harmful, resource-intensive production is growing. However, the real resistance often comes from within—from decision-makers who fear they aren’t appealing enough to the mass market or from quality control teams who struggle with the lack of clear, measurable standards for evaluating these new, inherently variable materials.

What else is there besides speckles, marbling and degraded surfaces?

One way forward is to better blend mainstream and sustainability. For example, what if we went the other way from random speckles and created something truly durable, taking into account the parameters of plastic manufacturing, to potentially achieve broader appeal than the current speckle approach while still using recycled materials? For example, instead of randomly distributed speckles, you could use fine, evenly distributed waste particles. This would be an evolutionary adaptation where the end result looks almost the same, but the consumer understands the subtle difference.

People want to buy products that are kinder to the planet – but they also care about how their products look and feel. There’s certainly a novelty factor in many of these aspects – sustainability has some great stories to tell about newness and innovation. Many consumers are enticed to purchase simply by the novelty of an item. This is where we, as CMF designers, come in. It’s the designer’s job to create desirability and make us fall in love with a product. This is why customers pay for design. In the context of sustainability, our job as designers isn’t just to make things look good, but to make the sustainability story a joyful, desirable one. It’s about changing the narrative so that responsible materials aren’t seen as a compromise, but as something worthwhile and beautiful.

Of course, we can’t achieve this alone. It will require a shared learning curve, with industrial designers, CMF specialists, materials scientists, and plastics and surface manufacturers working together more closely than ever before.

Together we must develop a new aesthetic language – one that makes sustainability visible, honest and desirable.

The spirit of the guided tours he’ll be leading at K2025 is exactly this. As a beginning point for this fascinating new trip, he has put together a list of the most creative and progressive solutions for sustainable plastics, materials, and surfaces—technologies that are presently accessible to all of us. The objective is to provide designers at K in Düsseldorf new ideas, practical examples, and the resources they need to create a future where sustainability and high-quality design coexist.

It’s time to redefine what beauty and value look like – starting with the materials themselves.

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

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ENGEL Enters New Growth Phase with Roegele Takeover and Creation of ENGEL Spain

ENGEL Enters New Growth Phase with Roegele Takeover and Creation of ENGEL Spain

The Spanish injection molding machine company ENGEL is acquiring its long-standing sales partner Roegele on April 1, 2026, as part of its ongoing internationalization plan. With this action, ENGEL expands its market share in southwest Europe and creates a new subsidiary, ENGEL Spain.

Graeme Herlihy, Regional President EMIA

Barcelona-based Roegele, S.A. is one of ENGEL’s oldest distribution partners. Since 1972, the company has supported customers across all key sectors of plastics processing – from automotive to medical technology. Their collaboration has been defined by a close and trusted partnership for over five decades. Roegele has independently managed sales, service, training, and consultancy on site. Most recently, over 90 percent of the company’s business was centred around their products. With the upcoming retirement of owners Bernd and Kai Roegele, a sustainable succession solution was required. The acquisition by ENGEL represents the logical and appropriate next step.

Strategic milestone in the growth market of Spain

Spain is one of Europe’s most important plastics markets – both in terms of volume and revenue. They have  a particularly strong presence in the automotive sector and ranks among the market leaders. Other sectors, such as packaging, medical, and technical moulding, also offer significant growth potential.

“We see considerable potential in Spain – not only in packaging but also in technical injection moulding. With ENGEL Spain, we are creating the conditions to expand into new customer segments, enhance our service responsiveness, and strengthen our market position in the long term,” says Stefan Engleder, CEO of the ENGEL Group. “Following more than 50 years of successful partnership, this acquisition is a logical next step.”

Strengthening local presence

ENGEL Spain will be integrated into the global ENGEL Group as an independent subsidiary. All Roegele employees will be retained. This integration fits seamlessly into ENGEL’s strategic focus: our customers’ needs are our top priority – which is why ENGEL continues to invest in customer-centric structures worldwide. Strengthening the local service and application technology teams will enable ENGEL to deliver targeted added value. The integration highlights a clear commitment to listening and providing tailored solutions to support customers’ long-term success.

“We aim to leverage our direct market access to strategically expand sales and be even closer to our customers,” emphasises Graeme Herlihy, Regional President EMIA. “Roegele has done outstanding work over the past decades. They have represented us across all areas of our technology – from compact e-mac machines to large-scale systems. This provides a strong foundation on which we are now building.”

Barcelona site: space for growth and development

The site in Barcelona – Roegele’s current headquarters – will be upgraded and, thanks to its generous size, offers excellent conditions for future development. The approximately 600 m² production area offers a wide range of potential uses.

With the establishment of ENGEL Spain, ENGEL is now represented by its own subsidiaries in all major markets in southern and western Europe. Direct proximity to customers, local expertise, and close integration with ENGEL’s European network will enable even more focused support and continued development of the market.

https://www.engelglobal.com/en/

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Haitian’s Injection Molding Tech Fuels Leapmotor’s Smart Bumper Line

Haitian’s Injection Molding Tech Fuels Leapmotor’s Smart Bumper Line

The fully automated turnkey bumper production project—jointly developed by Leapmotor’s Resin Production Division and Haitian Plastics Machinery—was officially commissioned. As the second fully integrated solution delivered to Leapmotor, this project is centered around Haitian’s self-developed HA41000-28900 ultra-large injection molding machine. The solution integrates full-process automation, marking the successful completion and production launch of Phase I, and establishing an intelligent closed-loop production cycle from raw materials to finished bumpers.

At the commissioning ceremony, Zhang Guangyin, General Manager of Leapmotor’s Resin Production Division, joined Xu Bin, Deputy General Manager of Haitian’s Global Industry Line, Liu Lizhu, Sales Manager of Northern Zhejiang Region, and Hu Haibo, Key Account Service Manager, to jointly launch the production line.

Phase I includes three HA33000-20200 systems and one HA41000-28900 system from Haitian. Each solution is equipped with automation technologies such as mold changing carts, magnetic platens, six-axis robots, gate cutting systems, automatic weighing, jig exchange platforms, laser marking, AGV transport, and automated warehousing. This enables fully intelligent production from material feeding and precise molding to downstream processing.

This partnership represents a powerful synergy between two industry leaders. Haitian’s cutting-edge injection molding and automation solutions have empowered Leapmotor’s bumper production, while Leapmotor’s forward-looking vision and manufacturing demands have created new opportunities for Haitian’s technical innovation. With the growing market demand for lightweight and personalized EV components, both parties will deepen their collaboration to explore the application of ultra-large injection molding systems in structural body parts, driving China’s smart manufacturing further up the global value chain.

https://haitianpm.com/en/

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Zygo’s Peter de Groot Selected for Distinguished 2025 Fraunhofer Optical Lecture

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Zygo’s Peter de Groot Selected for Distinguished 2025 Fraunhofer Optical Lecture

Zygo, an AMETEK business subsidiary, is pleased to announce that Dr. Peter de Groot, a former Chief Scientist at Zygo and now a Scientist Emeritus, will present the esteemed Fraunhofer Lecture at the 126th Annual Meeting of the Deutsche Gesellschaft für angewandte Optik (DGaO) this year. As part of the DGaO’s prestigious conference program, the lecture will be held at the Hotel Maritim in Stuttgart, Germany, on June 13, 2025, at 18:00.

Dr. de Groot has dedicated his career to the science and technology of precision measurement. Holding over 140 U.S. patents and recognized internationally for innovation in applied optics, his contributions share the stage with many outstanding advances in optical instrumentation for precision measurements.

In a lecture provocatively titled “Did I Invent That? Reflections on Creativity and Innovation in Optics,” Dr. de Groot will explore the true nature of invention. Drawing from a career that bridges basic research and the study of classical optics, he will discuss how many modern advances rest upon the foundational work of generations past, and examines the fine line between originality and reinvention.

“Innovation is often a reinterpretation of brilliant ideas that came before us,” Dr. de Groot says. “The core concepts of optical science such as coherence, interference, and holography, were explored long before today’s advanced light sources and detectors made them applicable to industries like semiconductor manufacturing and quantum imaging. To invent, one must first understand the past.”

Attendees can expect engaging stories from the frontiers of optical metrology, including insights into coherence scanning interferometric microscopy for surface mapping, heterodyne encoders for displacement measurement, manufacturing metrology, and interferometric micro ellipsometry. Dr. de Groot’s lecture promises to inspire both seasoned professionals and aspiring innovators, reminding all attendees that we stand on the shoulders of giants.

Zygo is also proud to be exhibiting at the associated DGaO exhibition, showcasing its latest innovations in optical metrology.

www.zygo.com

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Transforming Industry with Metallised 3D-Printed Polymer Technology

Transforming Industry with Metallised 3D-Printed Polymer Technology

Metalization of 3D-printed or 3D microfabricated polymer components has long been considered an attractive but ultimately unreliable method for industrial use. Many engineers have completely rejected the notion due to issues with the printed part’s mechanical robustness and outgassing, the part’s adhesion and thermal expansion mismatch, and the metallized layer’s environmental durability. Scepticism has only been strengthened by unsuccessful attempts.

Companies from a variety of industries have experimented with metallization methods for 3D-printed polymer-based components, with varying degrees of success. For instance, I have witnessed attempts to create mm-wave components for defense applications fail because of coating instability in harsh environments. In a different case, I recall a startup that made progress on employing metallized polymer components in space applications but eventually gave up, most likely because of problems with process instability.

These cases highlight the key reasons for industry scepticism. Many previous attempts have suffered from inconsistent coating performance, where adhesion failures and uneven deposition led to unreliable results. In other instances, environmental vulnerabilities became evident when components exposed to extreme temperatures, humidity, and mechanical stresses failed to maintain coating integrity. Additionally, limited long-term stability has been a major issue, with outgassing, mechanical degradation, and loss of electrical performance affecting many projects that initially seemed promising.

Tackling Perception Concerns

At Horizon Microtechnologies, our expertise suggests to us that the challenges surrounding metallisation can be overcome if the underlying problems are understood correctly. Our proprietary copper coating process is designed to overcome historical failure modes, but we know that claims alone are not enough. Rather than relying on unproven assumptions, we are committed to a rigorous, evidence-based approach to validation. The only way to change industry perceptions is through hard evidence.

That is why we are embarking on an intensive six-month testing program to systematically address the major concerns that have hindered adoption in the past. Each test will simulate real-world operating conditions primarily for (but not limited to) RF and mm-wave applications in the demanding aerospace sector. Horizon will evaluate its coatings under extreme environmental conditions by exposing them to sudden temperature changes and sustained humidity cycles. In addition, mechanical stresses will be assessed through vibration tests, and outgassing will be examined while exposure to atomic oxygen will simulate the harsh conditions encountered in space applications in low-earth orbit.

Other important tests will focus on compatibility with high-temperature assembly processes will be evaluated through reflow and adhesion tests, ensuring that the coatings maintain their integrity even when subjected to industrial soldering conditions.

Transparency

A key aspect of this initiative is transparency. Horizon Microtechnologies will publish the results of each test, providing the industry with concrete data to evaluate the viability of metallised polymer components. By removing ambiguity and speculation, this approach will allow engineers and designers to assess the material’s suitability for specific applications, from aerospace to telecommunications and advanced electronics manufacturing.

Historically, scepticism has been reinforced by the lack of detailed and accessible validation data. Many attempts at metallisation have been conducted behind closed doors, with findings remaining proprietary or incomplete. This opacity has left potential adopters without the necessary confidence to fully explore the technology’s potential. By openly sharing our findings, Horizon seeks to challenge not only technical limitations but also the industry’s perception of reliability.

The Future for RF & mm-Wave Applications

The ability to metallise complex, lightweight polymer components has profound implications for high-performance applications. In the RF and mm-wave sectors, where traditional metal components present significant weight and manufacturing constraints, the introduction of validated, high-quality alternatives can revolutionize design possibilities.

By way of example, we can consider a directional antenna such as a horn or array antenna to be used in a portable or mobile application such as a UAV payload. Here, every gram of antenna weight is one less gram available for electronic components. On the other hand, basic physics considerations impose a direct relation between the antenna size and its directionality, meaning it can’t be reasonably miniaturized without impacting functionality. This leaves the substitution of metal by metallised polymer as the only option to reduce weight.

When we pass these comprehensive tests, Horizon will not merely ‘claim’ success in the performance of its metallisation process — it will have ‘demonstrated’ success via passage through established testing methods and performance tests of devices pre- and post-environmental testing. Our aim is to show that metallised 3D-printed polymer parts should no longer be seen as an experimental risk. Instead, they will emerge as a proven, high-performance alternative, offering new pathways for industries that require advanced manufacturing solutions.

The results of these tests will establish a new benchmark, transforming industry perceptions and unlocking new possibilities for engineers and designers worldwide.

The time for scepticism is over. The era of proof begins now.

www.3dmicrofabrication.com

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iSeries Extruders from STEER World Target India’s Fast-Growing Plastics Market

iSeries Extruders from STEER World Target India’s Fast-Growing Plastics Market

  • New extruder platform offers smart, scalable, and cost-efficient compounding for India’s growing polymer industry
  • Affordable, high-performance compounding systems to power India’s plastics growth across automotive, infrastructure, consumer goods, and packaging

The latest twin-screw extruder line from STEER World, a leader in materials transformation technology worldwide, is called the iSeries. The iSeries was created especially for value compounders and newcomers to the Indian plastics market. It offers unparalleled dependability, streamlined upstream and downstream integration, accelerated speed-to-market, and optimum cost-performance.

While maintaining the fundamental engineering excellence that has made them a market leader in high-performance compounding, the iSeries offers standardized solutions designed for general-purpose applications like Color and Filler Masterbatches, Engineering Polymer (EP), and Polypropylene (PP) Compounding. These solutions are based on STEER World’s well-established Mega and Omega platforms.

“With the launch of the iSeries, we are redefining the benchmarks for accessible innovation in plastics compounding. This platform embodies our commitment to empowering value compounders with smart, scalable, and reliable technologies, bringing the power of high-performance compounding to the very heart of India’s manufacturing landscape”, said Sunil Dutt, Vice President of Sales at STEER World. 

Through the iSeries, they seek to bridge a crucial gap in the compounding ecosystem by providing affordable, high-performance systems that support India’s increasing demand for plastics processing in automotive, infrastructure, consumer goods, and packaging.

“STEER World’s new iSeries is precisely what the industry has been waiting for – exceptional performance, dependable reliability, and effortless integration. It brings all of this together in a smart, scalable, and cost-efficient solution”, said Dr. Pradeep Bakshi, Consultant – Plastics Technology.

The iSeries boasts a host of compelling features tailored for the Indian market:

  • Inspired by Proven Platforms: Draws on the engineering DNA of STEER World’s Mega & Omega platforms
  • Standardized and Optimized: Pre-engineered for efficiency, with minimal configuration needs
  • Best-in-Class Components: Equipped with STEER World’s high-precision elements, barrels, and shafts
  • Seamless Integration: Easily Integrates with both upstream and downstream systems
  • Technical Expertise at Every Step: End-to-end support for design, integration, and implementation
  • Fast Manufacturing Turnaround: Industry-leading lead times for delivery and commissioning
  • 100% Made in India: Designed, developed, and manufactured entirely in India for Indian manufacturing environments

The unveiling at PlastAsia 2025 saw tremendous interest from industry players, with multiple consultations showcasing how the iSeries could help manufacturers scale efficiently while controlling operational costs.

https://steerworld.com/

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Borealis Introduces Eco-Friendly Reusable Cup System at Messe Düsseldorf with OMV’s ReOil

Borealis Introduces Eco-Friendly Reusable Cup System at Messe Düsseldorf with OMV’s ReOil

  • The Messe Düsseldorf (Düsseldorf Exhibition Center) will use reusable cups at all restaurants and bars throughout K 2025, made from Borealis modified polypropylene for foam, which is produced using chemically recycled feedstock based on OMV’s ReOil technology
  • This marks the first time the venue uses a comprehensive reusable cup system, representing a significant step towards reducing waste from single-use cups at large-scale events
  • This pilot initiative will assess reuse and recycling rates, providing valuable insights for the effective implementation of scalable reuse systems at future events

Messe Düsseldorf is dedicated to cutting waste at major events. In an effort to create a sustainable solution that can be expanded for future events, reusable cups will be introduced for the first time at K 2025, the world’s premier international trade show for rubber and plastics. Borealis is contributing to this effort by offering high-performance modified foamable polypropylene (PP) that is especially well-suited for applications involving recyclable and reusable cups.

An additional sustainability advantage comes from the use of chemically recycled feedstock based on OMV’s ReOil technology. This initiative represents a significant step towards reducing single-use packaging at global exhibitions, aligning with the objectives of the EU’s Packaging and Packaging Waste Regulation (PPWR).

“ReOil is our proprietary chemical recycling technology that converts end-of-life plastics into circular feedstock for the production of chemicals, in particular new plastics,” says Maximilian Grasserbauer, OMV Senior Vice President Circular Economy. We operate ReOil at our Schwechat refinery close to Vienna, Austria, and are continuously investing in advancing this technology to ensure a reliable supply of circular feedstock for the market. ReOil is part of our sustainable base chemicals portfolio, designed to support our industry’s shift toward circular feedstocks.”

Beyond reusability and recycled content, the cups contribute to the circular economy in multiple ways: they are lightweight and material-efficient, have a reduced carbon footprint, and are fully recyclable.

“At Borealis, we are committed to creating innovative solutions in collaboration with our value chain partners and this initiative is a prime example,” says Peter Voortmans, Borealis Vice President Marketing Consumer Products. “Reuse systems are key to making large-scale events more sustainable, and our polypropylene solutions for foam support this by enabling lightweight, durable, and fully recyclable applications that use less material than conventional alternatives.”

During K Fair, the cups will be available deposit-free at all restaurants and bars across the site. To support reuse, Messe Düsseldorf will install special collection containers. Visitors can return the cups to service points, place them in the collection containers, or take them home for personal reuse.

Logistics staff will ensure that cups left on tables or placed in the collection containers are retrieved, rinsed in on-site kitchens, and returned to service. Any cups disposed of in general waste bins will be collected after the fair and recycled by Borealis. Unused cups will be donated for further use.

Thomas Franken, K Director, Portfolio Plastics and Rubber, Messe Düsseldorf, explains the motivation behind the initiative: “Introducing reusable cups to replace single-use cups at K 2025 aligns perfectly with our motto, ‘The Power of Plastics! Green – Smart – Responsible.’ As the global forum shaping the future of plastics, K 2025 provides the ideal platform to highlight practical initiatives that reflect the industry’s commitment to sustainability – while also supporting Messe Düsseldorf’s own sustainability goals.”

The initiative will serve as a pilot for assessing the effectiveness of scalable reuse systems at large events. Messe Düsseldorf will analyze usage patterns, tracking how many cups are used, re-used, and recycled. The insights gained will contribute to the development of more sustainable solutions for future events, since reducing emissions and waste from operations is a key objective of Messe Düsseldorf’s sustainability strategy.

This collaboration has been further supported by additional partners who contributed to cup production and the integration of durable in-mold labels.

ArburgSpecializing in manufacturing high-end injection molding machines and turnkey systems for plastics processing.

Bockatech: EcoCore foaming technology, used for the durable injection molded cups, reduces plastic use by up to 50%, doubles the thermal insulation, cuts manufacturing time and provides 5x the strength while ensuring recyclability.

MCC Global IML: Producing sustainable in-mold labels for rigid plastic packaging, focusing on innovation and circularity.

Miko Pac: Developing and producing innovative plastic packaging solutions for various industries, including food service.

www.borealisgroup.com

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Modernized and Optimized: TOP 5100 LSR Dosing System Makes a Confident Comeback

Modernized and Optimized: TOP 5100 LSR Dosing System Makes a Confident Comeback

Elmet‘s most recent liquid silicone rubber (LSR) injection molding precision dispensing machine is the TOP 5100. It falls into the high performance range of the manufacturer’s dispensing systems and is compatible with drums that are 20 and 200 liters in capacity. It replaces the TOP 5000, the previous model that has been a global success for nearly a decade. The 20-liter TOP 700 system is the first in the product line, followed by the fully functional flagship TOP 7000 for 20- and 200-liter containers, to which the new TOP 5100 is conceptually closely connected. Elmet has decided to demonstrate its new dispensing system at Silicone Expo Europe, which will be held in Amsterdam on March 19 and 20, 2025.

Further advancements over its predecessor include the TOP 5100’s smaller, more space-efficient design, pump technology with improved sealing for an even longer service life, the volume meters’ higher resolution for even more production precision, and the updated, thus more efficient, software. Employee protection is maximized when the highest safety standards (EN ISO 13849-1) are followed. FDA compliance is an optional design option for the CE and UL-certified TOP 5100. Elmet’s dosing systems and the parts of them that come into touch with the substance must be free of phthalates in order to be used in the food, medical, and associated sectors.

For users who use both TOP 5100 and TOP 7000 units, the conceptual similarity of both systems enables them to reduce spare parts inventory.

The new TOP 5100 is equipped with the M pump unit, which was introduced at Fakuma 2024. This enables a delivery pressure increased to 230 bar, allowing the processing of all commercially available LSR materials in an expanded viscosity range from 0.001 Pas to 3000 Pas. This includes carbon black or mineral-filled and self-adhesive materials that tend to increase in viscosity, as well as abrasive materials, such as thermally conductive materials for e-mobility.

Efficiency thanks to flexibility, precision, and durability.
The TOP 5100 is equipped with the same flow-optimized processing unit and additive system that characterize all other Elmet LSR dosing systems. Flow rates of more than five liters per minute enable short cycle times when filling both larger molded parts and high cavity counts.

The modular design of the processing unit with integrated cooling and the user-friendly clamp connection of the elements facilitate cleaning and maintenance. The volume counters, with their high resolution of 3.9 μl per pulse, provide additional process stabilization when mixing components A and B.

The TOP 5100 is equipped with the option of connecting a regulated additive line as standard; up to five additional ones can be retrofitted. The supply can be optionally provided from 1-, 4-, or 20-liter additive containers. The high resolution of the additive volume counters of less than 0.1 μl/lmp represents a benchmark for maximum precision when adding additives, which is particularly required for very small components.

Up to 99.6% material utilization per container, the high conveying capacity and the low maintenance costs ensure high economic efficiency over the entire service life, which, thanks to the use of high-quality components, is often twenty years or more.

Lukas Linimayr, Product & Business Development Manager at Elmet, commented: “The wide range of available options, coupled with solid conveyor technology must-haves, makes the new TOP 5100 the all-rounder among our dosing systems. It is suitable for standard applications as well as, depending on the configuration, for special, customer-specific requirements. Regardless of this, it stands for maximum process stability and mixing precision for excellent part quality and exceptional cost-effectiveness.”

https://www.elmet.com/

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LSR Molding Enhanced with Intelligent Servoelectric Cold Runner Systems

LSR Molding Enhanced with Intelligent Servoelectric Cold Runner Systems

An intelligent variation of the SMARTshot E system is the patent-pending SMARTshot I cold runner measurement and control concept, which is being developed by LSR mold expert Elmet and incorporates servoelectrically actuated nozzle needles. Completely automated startup will be feasible once implemented in a real-world environment, as will controlled family molds with varying-volume cavities that don’t need extra sensor systems. This will allow for the simultaneous filling of cavities with varying volumetric flow rates per nozzle using injection processes with partially open needles and cascaded injection processes with time-delayed opening and closing actions. Elmet will present an update on this novel idea at LSR 2025, which will take place in Irvine, California, from June 16 to 19.

At its launch at Fakuma 2021, SMARTshot E was one of the first all-electric, servomotor-driven cold runner system for processing liquid silicone rubbers (LSR).

The SMARTshot-I development concept is based on the same technology. However, additional rheology-based features will be able to further improve controllability of the injection molding process by using AI with self-learning functionality.

It will be possible to set up or retrofit this upgrade on any existing SMARTshot E mold. In combination with compatible injection molding machines that have a suitable interface, it will then be available to any user. SMARTshot I will be the ideal add-on to the type E in future. Elmet’s range of valve gate cold runner systems also includes the pneumatic SMARTshot P and the hybrid SMARTshot PE with pneumatic needle movement and electric stroke adjustment.

Getting there faster and more reliably with self-learning

The pioneering “I” technology is based on online rheometry for continuously optimizing the process and determining the actual material viscosity in the shear rate range of relevance to injection molding. This technology uses a mathematical relationship between the volumetric flow rate of the injection molding machine, the geometric constraints of the cold runner, and the shear force at the needle to identify and quantify batch-to-batch fluctuations. This turns the cold runner into rheological measuring instrument.

In learning mode, the system automatically detects the volume of material required to fill a cavity, so facilitating setup and optimization, especially with family molds with a number of cavities of differing sizes. Ready for integrating artificial intelligence (AI), the system is set in future to be able to support self-controlled injection molding machines if SMARTshot I control is integrated into the machine at a later date.

Micrometer-range precision

In type E and I systems, servoelectric drives perform the tasks carried out by the pneumatic pistons that were until recently used as standard. This is achieved using a highly responsive, brushless 24 V, 50 W DC motor that generates minimal waste heat and can withstand three times the rated load for short periods. As one of the smallest and most compact drives currently on the market, it allows particularly narrow nest spacings from 44 mm. The effective stroke is 4 mm, and the system achieves an accuracy of 0.09° per revolution, so reducing the error range to ± 0.05% or ± 0.002 mm. Compared to pneumatic systems, this enables significantly faster and more precisely controllable needle movement and positioning and minimizes shot-to-shot deviations. In addition, active needle control assists with uniform cavity filling, even if the cold runner is not perfectly balanced, and with cascading the injection phase by delaying needle opening or extending injection.

One of the general advantages of the servoelectric drive is real-time control of needle position, including permanent position monitoring. The anti-twist feature of the needles means that the geometries of the needle tips can be adapted to the contour of the cavity, so minimizing marks at the injection point. Needle opening can be adjusted to an accuracy of 0.002 mm. Needle opening and closing times are of the order of hundredths of a second, and the needle movements at different injection points can be perfectly balanced.

Nearly ready for showtime

At its current stage of development, the control software used for SMARTshot I enables precise measurement of cold runner signals and individual and dynamic adaptation of needle stroke to each cavity’s specific requirements. In tests with a 16-cavity mold, the cold runner could be fully automatically balanced within 20 shots to such an extent the components produced only exhibited minimal weight fluctuations of 1.5%. In addition, a reduction in process startup times of around 90% compared to manual adjustment by an operator would seem to be realistic. The forthcoming increase in CPU capacity will enable further improvements in this respect.

As development manager Thorsten Häuser explains, “Our aim with SMARTshot I is to significantly automate setup of the LSR injection molding process and make it more user-friendly. We are also taking the first step toward introducing artificial intelligence, firstly into the mold and later into LSR processing as a whole. This will be a considerable benefit to users by saving personnel time and financial expenditure, not only on setup and startup of new production runs but also in terms of ongoing error prevention. In future, AI will also assist with further automating and boosting the efficiency of LSR injection molding processes and will ensure we’re always pushing the envelope despite any potential stumbling blocks.”

http://www.konsens.de

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