< PreviousI KraussMaffei advances continuous PU chemical recycling To address the tightening outlook for thermal treatment of plastics, KraussMaffei, together with BASF, Rampf and Remondis, is industrialis- ing a continuous chemical recycling route for polyurethane insulation foams from end-of-life refrigera- tors. The approach, based on depol- ymerisation via a modified glycoly- sis run in a co-rotating twin-screw extruder, is designed to handle heavily contaminated PUR regrind, including residues of other plastics and metals at levels up to 30%. In the purity glycoLine PU process, regrind from Remondis’ refrigera- tor recycling operations is metered with depolymerisation agents and additives into a ZE BluePower ex- truder, where polymer chains are broken down within minutes to form an intermediate. Foreign sub- stances are then removed directly in-line through filtration adapted by KraussMaffei to meet polyol mar- ket requirements. The resulting recycled polyols can be used at BASF as components in rigid foam systems with recycled content. The partners indicate that the process is already economically attractive. At K 2025, KraussMaffei plans to demonstrate live processing of the PU system with recyclate content into foamed beverage insulators, and will also introduce a RimStar metering machine prepared for digitalisation and future autono- mous operation. The Circular Valley Convention will re- turn on 11 and 12 March 2026, bring- ing decision-makers and circular econ- omy practitioners back to Düsseldorf and the Areal Böhler. Following its debut in March 2025, which gathered more than 100 ex- hibitors and 200 speakers, the 2026 edition again combines a specialist conference, a practice-oriented expo and targeted networking. Four global companies, BASF, Bayer, Evonik and Henkel, are confirmed as co-hosts. Together with additional partners, they underline a cross-industry and cross-sector approach to circularity and signal support for solution-driven collaboration across value chains. The program highlights circular value creation throughout the product life cycle, from design and material se- lection to digital applications and re- cycling technologies. Registration for exhibitors and partners is open to companies, start-ups, research institu- tions and NGOs that aim to present solutions in the expo area or on the conference stage. As co-hosts and early movers in the circular economy, BASF, Bayer, Evonik and Henkel will contribute through exhibition stands, best practice exam- ples in the expo area and expert con- tent with high-profile speakers on the conference stages. “The circular economy is the key to a sustainable future, and at Bayer we are actively committed to devel- oping innovative solutions that both conserve resources and minimise our environmental footprint. The Circular Valley Convention 2026 offers a valu- able opportunity to come together with other thought leaders to explore new approaches and actively drive the transformation towards a circular economy. Only through collabora- tion and the exchange of best prac- tices can we master the challenges of the future”, said Dr. Holger Weintritt, Head of Pharmaceuticals Product Supply, Bayer AG. “The Circular Valley Convention is a unique platform to connect ideas, talent, and industries, dimensions of strategic relevance for Henkel. By connecting science, industry, and partners across the value chain, we can accelerate scalable solutions that drive the circular economy, sustaina- ble growth and lasting impact”, added Frank Meyer, CSVP R&D & Sustain- ability Henkel Consumer Brands. The convention’s format combines a high-calibre conference with prac- tical demonstrations and networking to facilitate dialogue and cooperation. The agenda focuses on actionable ap- proaches to circular value creation, cross-industry collaboration and in- novation across the entire life cycle. Topics explicitly include design for cir- cularity, material use strategies, digital applications that enable transparency and efficiency, as well as recycling technologies that close loops. This mix is intended to promote exchange be- tween business, science, politics and civil society, with the goal of translat- ing concepts into scalable solutions. I Circular Valley Convention comes back in March 2026 Plast Echo10I KHS analyses bottle and machine parameters using simulation High-capacity beverage filling can lead to liquid sloshing when rotation speed and changes in direction act on the contents of the bottle, especially at the handover from the filler to the transfer star and on to the capper. Even when this amounts to only a few drops per container, the cumulative loss becomes significant at throughputs of up to 90,000 fills per hour. Beyond efficiency, hygiene is af- fected as sugary beverages can soil necks and closures, in some cases promoting mould formation, while machine components become contaminated. This increases cleaning requirements and shortens available production time. To counter these issues, KHS bases machine design decisions on extensive calculations that predict and mitigate sloshing behaviour under realistic operating conditions. Since 2013, KHS development engineer Dominik Weirich has been preparing calculations to incorporate liquid dy- namics into the engineering workflow. “Ever higher filling outputs mean that the technology’s reaching its physical limits, so that we also have to take liquid sloshing into ac- count when designing the machine”, says the KHS develop- ment engineer at the factory in Bad Kreuznach, Germany. Data from these simulations feed directly into machine de- sign and into commercial offers for new lines. The calculations address two parameter groups that govern sloshing risk and can be adjusted to varying degrees during a project. •Geometric parameters of the containers: the influence of bottle shape, fill height and neck diameter is evalu- ated. This work is done in close consultation with Bot- tles & Shapes experts, particularly in new line projects that modify geometry or reduce bottle weight. •Physical parameters of the machines: capacity, ma- chine pitch and the diameter of the stars are consid- ered. These settings can usually be adapted relatively easily compared to container changes, which tend to be iterative and more extensive. th ANNIVERSARY Storage, conveying and gravimetric dosing on 53 injection moulding machines. POLAND the challenge goes on... Hall 11 Stand E68 Moretto East Europe Tel. +48 0 343 903 615 info@morettoeasteurope.com www.moretto.comI TotalEnergies and CooperVision use ISCC Plus PP in lens packs TotalEnergies and CooperVision have taken their more than 20-year collaboration a step further by introducing ISCC Plus-certified polypropylene into blister packs for certain CooperVision contact lenses. Under CooperVision’s “Plas- tic Made Better” program, TotalEnergies supplies certified renewable polypropylene implemented via a mass balance approach. The bio-certified polymer is derived from the processing of renewable feedstocks, primarily sunflower and rapeseed oils, at TotalEnergies’ bio-refinery in La Mède, France. By using mass balance, the environmental benefits of the renewable inputs can be allocated across the value chain, which enables CooperVision to improve the environ- mental footprint of its packaging without altering the origi- nal materials or compromising performance. The ISCC Plus-certified polypropylene is part of TotalEner- gies’ RE:newable range. According to a cradle-to-gate life cycle analysis conducted by TotalEnergies, RE:newable polypropylene grades can allow a reduction of 2.3 kg CO2eq per kilogram of polypropylene when replacing its fossil-based equivalent from TotalEnergies. The company positions this collaboration as supportive of its ambition to produce 1 million tons of circular polymers in 2030. ISCC Plus certification and the mass balance methodology are central to the approach. Mass balance allows TotalEn- ergies to allocate the environmental benefits of renewable feedstocks across the value chain. This enables the use of certified renewable polypropylene in existing blister pack formats, without altering materials or performance, for se- lected CooperVision lenses. “This collaboration to Coopervision’s ‘Plastic Made Better’ effort demonstrates how TotalEnergies supports the sus- tainability ambitions of a long-standing partner. Enabling the valorisation of bio-certified polymers in high-value ap- plications, such as in the medical device sector, also show- cases our commitment as a company to promote the circular economy and fully supports our ambition to produce 1 mil- lion tons of circular polymers in 2030,” said Olivier Greiner, Vice President Polymers Europe & Orient at TotalEnergies. “At CooperVision, we are taking steps to minimise our en- vironmental impact and operate more sustainably,” said Aldo Zucaro, Senior Director of Corporate Responsibility at CooperCompanies. “Working with TotalEnergies to support our ‘Plastic Made Better’ effort means our customers and patients can participate in our sustainability journey by just choosing participating CooperVision contact lenses”. Limited installation space is a recurring constraint in mould- making, where every millimetre affects assembly and op- eration. Hasco has released the plug insert H12294 for 12 control zones, designed to utilise available space without compromising electrical performance. Despite the increased connection density, the insert re- tains a maximum load capacity of 16 A. It is intended to replace large, complex connection boxes with a compact interface, while keeping the mounted housing identical to earlier 6-zone variants. A key benefit of the design is that only half of a bulkhead mounted housing is required. This can be advantageous in small, compact moulds and also in large multi-cavity injection moulding tools, in which con- nection boxes often protrude from the mould and compli- cate assembly. By shrinking the footprint of the connection hardware yet maintaining current-carrying capability, the insert addresses typical integration challenges in hot run- ner-equipped tools. The plug insert uses crimp technology to secure cables. The wires are permanently compressed in the pins, providing a reliable connection, yet can be removed from the plug with the appropriate tool for rewiring when required. This approach enables fast changes to wiring layouts and is in- tended to support safety, reliability and long service life. To complement the insert, Hasco Hot Runner supplies coor- dinated cables. On request, these can be provided as a con- necting cable with compact pin assignment on one side and the usual wiring on the other, allowing existing control technology to continue in use without modification. I Hasco plug insert enables 12-zone control in compact housings Plast Echo12I Universal Robots introduces UR8 Long cobot with 1750 mm reach Universal Robots unveiled the UR8 Long, a long-reach col- laborative industrial robot designed for the most demand- ing automation tasks in confined spaces. The new model, first shown at the Fabtech trade show in Chicago, combines a 1750 mm reach, identical to the UR20, with a lightweight design and an 8 kg payload. The extended reach, together with coordinated multi-axis motion, enables complex welds with consistent quality. Optimised motion profiles deliver smoother movements at maximum speeds, improving bin- picking throughput. The manufacturer reports that the UR8 Long is already available for purchase, with shipments starting in October. Thanks to its compact build and 30% lower mass than the UR20, the model is intended for tight workcells and for mounting on gantries, rails, and overhead systems, where external axes can operate more efficiently. Applications include, among others, welding, case packing, and multipoint quality inspections. The UR8 Long works with both PolyScope 5 and PolyScope X, Universal Robots’ software platforms. It can be extended with MotionPlus, a motion-control technology that enables integration with external linear axes and rotary positioners. This solution provides precise guidance, smoother trajecto- ries, and consistent accuracy. Using enhanced Freedrive functions, users can manu- ally guide the arm with high precision. This facilitates lead-to-teach programming and shortens setup, including for complex parts, without multi-layer interfaces or exter- nal tools. The lower mass and compact joints favor mount- ing on gantries, rails, and overhead systems, as well as in- verted mounting, broadening the range of applications. “The UR8 Long is an intelligent robot arm that can reach farther and perform more tasks than ever before. It was designed to help people and companies work faster, more safely, and with less physical strain”, said Jean Pierre Hath- out, President of Universal Robots. “Whether it’s lifting, moving, or performing repetitive or physically demand- ing tasks, this robot makes the job easier. Its longer reach means it can cover a larger workspace, and its advanced features open new opportunities to automate work that was previously done manually”. With its long reach, advanced motion control, high preci- sion and repeatability, the UR8 Long is aimed at welding processes. According to the manufacturer, the robot offers simpler programming than traditional welding robots, and weld quality is said to surpass manual welding. I Bole at K 2025: driving innovation in plastics processing At K 2025 in Düsseldorf, Bole will showcase groundbreak- ing injection moulding technologies under the theme “In- novations Driving Tomorrow’s Industry”. Visitors will expe- rience live demonstrations of solutions designed to boost efficiency, precision, and material savings. Highlights include the 250EKW-E EVOlution, a servo-hy- draulic multi-component injection moulding machine that enables faster, more economical production by combining multiple materials in one mould. With the CIML 200, Bole will demonstrate long-fiber injection technology for pro- ducing high-strength, lightweight parts, such as drone fan blades from PA + CF with fibers up to 15 mm. Another focus will be MTX Thixomolding, dedicated to magnesium alloys. As demand for lightweight yet durable components grows across automotive, electronics, de- fense, and consumer goods, magnesium thixomolding is rapidly becoming a preferred solution worldwide. In cooperation with a partner, Bole will also present the DK 200 with Water Injection Technology, a modern alter- native to gas injection moulding. This method allows the production of thick-walled parts while saving raw material and costs. Bole invites all visitors to K 2025 to discover how its tech- nologies are shaping the future of plastics processing. Plast Echo14I Continental first to use Lanxess’ sustainable rubber additive Continental has become the first tire manufacturer to use Vulkanox HS Scopeblue from Lanxess in the production of its tires. The ISCC Plus-certified additive is a more sustain- able version of the established Vulkanox HS (TMQ) antioxi- dant and is designed to protect rubber compounds during vulcanisation from oxygen and heat. According to the companies, the overall chemical structure of the Scopeblue grade is unchanged compared to the con- ventional product, so tire makers do not need to adapt their production processes. Lanxess reports a cradle-to-gate carbon footprint that is more than 30% lower, achieved by using bio-circular ace- tone as feedstock and renewable energy in manufacturing. The collaboration supports Continental’s materials strategy and aligns with its target of using over 40% renewable and recycled materials in its tires by 2030. “At Continental Tires, we are continuously working to im- prove the environmental performance of our products. Col- laborations like the one with Lanxess and the use of innova- tive rubber additives such as Vulkanox HS Scopeblue, help us move closer to our goal of using over 40% renewable and recycled materials in our tires by 2030,” said Steffen Ryssel, Head of Purchasing at Continental Tires. “We are delighted that Continental, a premium manufactur- er, has chosen our Vulkanox HS Scopeblue for its products. This shows that our innovative additives are recognised and valued in the industry. With solutions like these, we support our customers in developing the best possible products while achieving their climate goals”, added Dr. Jens-Hendrik Fischer, Head of Lanxess’s Rhein Chemie business unit. K Show 2025 Hall 6, Booth C58-03 TPE for demanding applications Discover our highlights and a proven product and service portfolio Discover KRAIBURG TPE www.kraiburg-tpe.com International Edition – K 2025 15Plast EchoAt K 2025, ENGEL is presenting an integrated, fully auto- mated production solution for the diagnostics market. The system achieves an increase in overall efficiency of approxi- mately 25% compared to conventional production meth- ods. In a single cell, well plates and lids are produced and packaged in a validated manner. At the heart of the solution is an all-electric ENGEL e-motion 280 WP combi MW injec- tion moulding machine with 2800 kN clamping force. ENGEL’s compact system concept combines with the in- novative high-performance Variotwinstack mould technol- ogy from HACK Formenbau GmbH to implement the prin- ciple of two machines in one. The mould is designed for the simultaneous production of up to four polystyrene well plates with 24 wells and their matching lids. For optimal media connection, the e-motion features a movable cen- tre platen. The two injection units operate in parallel – not sequentially – reducing the cycle time to just 11 seconds. The shot weight for the well plates is 42.6 grams, and 13.2 grams for the lids. The angled arrangement of the moving injection unit brings the nozzle closer to the hot runner, reducing its volume and thus increasing process reliability. Valve gate hot runner injection without a sprue optimises material usage while completely eliminating weld lines and flow marks. A multi- stage demoulding process with intelligent cooling and op- timal part orientation further provides a particularly wide process window. In addition, integrated HACK moldlife sense sensor technology continuously monitors the mould mechanics, increases system availability and detects faults at an early stage. This system also supplies data to support digitally assisted process validation. One of the key advantages of this production solution lies in its reduced system height, made possible by the newly designed layout. The overall footprint of the production cell is reduced by 40% – a significant cost-saving factor in cleanroom environments, where floor space comes at a premium. ENGEL’s e-motion series has been specifically developed to meet the most demanding requirements in injection mould- ing for medical technology and sets new standards in preci- sion, efficiency and long-term cleanroom performance. I ENGEL presents fully automated production solution for the diagnostics market Wittmann Battenfeld is set to present a comprehensive portfolio of injection moulding solutions at K 2025 in Düs- seldorf, under the theme “Smart Choices – Smart Savings.” Visitors to booth B22 in hall 15 will encounter a range of in- novations designed to optimise resource use, enhance pro- cess efficiency, and address current sustainability demands in plastics processing. For the first time, the entire Witt- mann Group will present its offerings together on a com- mon booth, reflecting the company’s integrated approach to machinery, automation, and digitalisation. The highlight of Wittmann Battenfeld’s exhibition will be the new MacroPower 500/3400, distinguished by its compact, one-piece machine body. This design innovation reduces installation time and space requirements, while the pivotable injection unit simplifies screw changes and maintenance. The MacroPower is equipped with the Unilog B8X control system, featuring in-house developed compo- nents that enable faster response times and improved part reproducibility. The new MacroPower series, available in clamping forces from 400 to 600 t, will be demonstrated by producing a “HAIBOX” from polypropylene (PP) supplied by Borealis, using a single-cavity mould from Haidlmair. The process in- tegrates in-mould labelling (IML) with labels from Viapiani and employs thermal imaging for quality control, with SKZ’s TD14.0 software ensuring only parts within temperature tolerances proceed to packaging. The company will also display a MacroPower 650/2250H/1330H Combimould with a 1500 mm rotary table, demonstrating multi-component moulding with two horizontal injection units. This setup produces a foldable laundry basket from PP and TPE using a 1+1-cavity mould from ATA Kalip ve Plastik, with a Primus 148T robot han- dling part removal and placement. I Wittmann Battenfeld presents smart injection moulding solutions at K 2025 Plast Echo16At K 2025, Sumitomo (SHI) Demag will showcase its most innovative and customer-oriented developments to-date, highlighting how the unique collaboration between indus- trial experts in Germany and Japan is advancing process ef- ficiencies. Customers who choose Sumitomo (SHI) Demag technologies become more agile – today, tomorrow, and beyond. Reinforcing the company’s commitment to a fu- ture supported by cutting-edge all-electric injection mould- ing machines. Aligned with the company’s new theme "Today. Tomorrow. Electric.", Sumitomo (SHI) Demag will showcase 8 all-elec- tric machines at K 2025, featuring options from the IntElect platform for manufacturers across all market segments. The company will also unveil two brand new PAC-E machines, designed as the ultimate all-electric fast-runners. Devel- oped on a global platform, these machines were created through close collaboration with electric drive specialists in Japan. Robotics will be another key focus across the main Sumitomo (SHI) Demag stand, alongside several process improvement solutions developed by sister company Leif- eld, also part of the Sumitomo Heavy Industries Group. The highlight at the Sumitomo (SHI) Demag booth is the debut of an all-electric 2K multi-component IntElect 350t machine combined with a SAM-C20 robot. The R-position offers a standard option for 220–500 t IntElect machines, with an adjustable nozzle distance providing added flexibil- ity. In response to processor demand for a top-entry robot offering greater stability and precision within a smaller foot- print, Sumitomo (SHI) Demag will showcase the benefits of partnering with a single supplier capable of managing the entire customisation, technology integration, and cell vali- dation process. This includes the installation of all safety- relevant components, machines, robotics, peripherals, and conveyor technology. Leading the shift towards all-electric in the fast cycle pack- aging market, the first 420-ton PAC-E machine will feature a packaging caps and closures demonstration with clean, digital inline cap printing. Developed by Swiss supplier CAPrint, this fast changeover personalisation proves that processors moulding 72 caps every 2 seconds can seam- lessly print and quality check customised designs for brand- ing differentiation and match the closure moulding speed. The production cell also comprises a 72-cavity tool from Z- Moulds, a mould area dehumidification system from Eisbär and a state-of-the-art inspection camera and box packing system from IMDVista. I Today. Tomorrow. Electric. Sumitomo (SHI) Demag at K 2025 At K 2025, Zhafir will present the Zeres medical, an all- electric injection moulding solution derived from the Zhafir Zeres series and equipped for regulated healthcare produc- tion. The GMP-compliant configuration includes GoFactory as standard. Its integrated interface enables process moni- toring and traceability at no additional cost, supporting vali- dation and documentation. A live application on a ZE1500V-300h medical with a 32mm screw will demonstrate production of a syringe barrel in cyclic olefin copolymer using an eight-cavity mould. With a 24 gram shot weight, the glass-like COC demands pre- cise temperature control and stable injection to achieve high dimensional accuracy. The Zeres medical addresses these requirements with an injection pressure capability up to 2,530 bar and a maximum injection speed of 300 mm/s to maintain consistent process conditions and repeatable quality. The cell is equipped with peripherals from Haitian Smart Solutions, including a dryer, a material handling sys- tem and a temperature control unit operating at a 110°C setpoint, and with cleanroom elements from partner Petek such as a fan filter unit, a laminar flow box and a fully en- closed conveyor for controlled part handling. Zhafir Plastics Machinery, founded in 2005, is a brand of Haitian International and focuses on electrical precision so- lutions in injection moulding. More than 33,000 machines have been installed worldwide to date, almost 30,000 of them in the last 10 years. I K 2025: Zhafir debuts Zeres medical with COC syringe demo International Edition – K 2025 17Plast EchoI MOL Group turns plastic waste into high value products MOL Group has achieved a significant milestone in its Shape Tomorrow strategy by successfully completing its first ISCC Plus-certified production run using circular feedstock at its MOL Petrochemicals site in Tiszaújváros, Hungary. The pilot test demonstrates MOL’s ability to convert circu- lar feedstock, namely post-consumer plastic waste-based feedstock into high-quality polyethylene (PE) and polypro- pylene (PP). This marks a major step in MOL Group’s Shape Tomorrow strategy to integrate circular economy into pro- duction and establish itself as a leader in sustainable petro- chemicals in Central and Eastern Europe. “This successful test shows that MOL Group can now pro- cess circular feedstocks according to ISCC Plus certified process, turning plastic waste into new, high-value prod- ucts”, said Péter Császár, Senior Vice President, MOL Group Chemicals. “It is a significant step towards sustainable pet- rochemicals and strengthens our position as a leading circu- lar economy player in Central and Eastern Europe”. During the pilot, circular feedstock based on post-consum- er waste was introduced to MOL’s steam cracker. This pro- cess allows the production of circular-based monomers and then converts them into polymers. During the process, the mass balance approach was applied, a methodology that tracks and accounts for circular material when processed together with traditional inputs, ensuring the balance of the total process flows. This achievement follows the ISCC Plus certification, which was achieved by MOL Petrochemicals in Tiszaújváros and Slovnaft in Bratislava in 2024 for steam cracker and poly- merisation units. Maximising synergies with waste manage- ment is central to MOL Group’s Shape Tomorrow strategy. The company aims to continue the transformation towards circular chemicals and to utilise up to 1.5 million tonnes of feedstock for the energy industry by 2030. This is sup- ported by a growing portfolio that includes a concession to manage municipal waste in Hungary, past acquisitions in plastics recycling in Hungary and partnerships to advance chemical recycling technologies. MOL Group will continue testing additional circular feed- stocks and developing new processes to expand the role of waste as a raw material for plastics production. I RecyClass certifies over half of Europe’s plastic recycling capacity Covering 60% of Europe’s installed plastics recycling ca- pacity, the RecyClass Recycling Process Certification has become the leading certification scheme for plastics trace- ability across the region in only 3 years since its launch. “The continued growth of this certification scheme is a clear indicator that RecyClass’ efforts to drive plastics circularity are delivering real impact. RecyClass Recycling Process Cer- tification has become the benchmark for companies seek- ing to certify their recycling processes and comply with the EN 15343:2007 standard”, affirmed Paolo Glerean, Chair- man of RecyClass. In 2024, the share of European installed recycling capacity certified by RecyClass at the stream level grew exponen- tially, reaching 58% for HDPE/PP, 62% for ELV-WEEE, 70% for LDPE, and 75% for PET. These figures underscore the plastic recycling industry’s commitment to operating under verified and reliable recycling standards, thereby providing the value chain with high-quality recycled materials. Today, RecyClass collaborates with 11 accredited and 7recognised third-party Certification Bodies, amounting to more than 120 auditors available to issue Recycling Pro- cess Certificates. In view of the legislative targets for re- cycled plastics outlined in the Single-Use Plastic Directive (SUPD) and Packaging and Packaging Waste Regulation (PPWR), recyclers seeking to demonstrate the traceability of their operations and ensure transparent communica- tion of the origin of plastic waste are encouraged to apply for certification. Plast Echo18Next >