My Highlights from K Fair 2025 – The Global Hub for Plastics & Rubber Innovation

Hello and welcome to a new post! The K trade fair in Düsseldorf once again proved itself as the ultimate meeting place for the plastics world—international, innovative, and truly immense. This year, I had the opportunity to witness some  developments that are shaping the future of our industry, particularly in the areas of sustainability, digitalization, and advanced materials.

K Fair 2025: My highlights and discoveries

My Key Discoveries:

🔹 China’s Growing Leadership:

Chinese plastics and rubber companies are not only increasing in number—up nearly 50% from the last event, now making China the second-largest exhibiting nation after Germany—but are also leading in innovation, product development, and circular economy initiatives. Their presence and technological advancements were truly impressive.

🔹 AI in Daily Production:

Artificial intelligence is no longer a buzzword; it’s now an integral part of daily operations. Connected machines and real-time data analysis are accelerating both the speed of innovation and speed to value across the industry.

🔹 Industry Transformation:

While revenue growth remains a challenge, this period is being used as an opportunity to streamline internal structures and consolidate portfolios, preparing for a more resilient future.

🔹 Energy Costs & Plant Closures:

High energy costs in Europe continue to impact the sector, leading to the closure of several chemical plants—a trend that cannot be ignored.

🔹 Recycling as a Sustainability Driver:

Recycling has evolved from a cost-saving measure to a key driver of sustainability, especially when combined with product carbon footprint passports and digital material twins.

🔹 M&A Activity:

Mergers and acquisitions remain active, with notable deals such as Engel’s acquisition of Trexel, a specialist in foaming technology for injection molding.

Let us deeper dive into the latest innovations in circular economy and recycling, digitalization and smart manufacturing, new materials, and machinery enhancements:

Circular economy and recycling innovations

Next-level recycling technologies: Companies like Gneuss showcased melt filtration and extrusion technologies designed to significantly improve recycling processes. The VDMA's Circular Economy Forum provided live demonstrations of implementing circularity within plastics production.

High-quality recycled materials: BioPlastics & Recycling GmbH presented certified post-consumer recycled (PCR) regranulates, including rPP and rPE with FDA approval, setting new standards for quality and sustainability.

Upcycled materials: Researchers showcased new materials, such as the BAETA technology, which transforms recycled PET bottles into carbon capture material.

Sustainable product design: Prototypes and commercial products were presented that were designed for better recyclability, including mono-material solutions and reusable systems. For example, Covestro and VAUDE introduced a recyclable, mono-material backpack made from TPU. 

Innovative recycling technology: Syensqo showcased its innovative recycling technology for circular sulfone polymers. 

Digitalization and smart manufacturing

Artificial intelligence (AI), the Internet of Things (IoT), and automation were on display to showcase the future of smart manufacturing. 

AI for efficiency and sustainability: Exhibitors highlighted how AI-based process optimization can increase the throughput of blown film lines, automatically coordinating components for greater efficiency. Reifenhäuser also introduced "Reifenhäuser Next," a brand centered on an AI chatbot and digital learning platforms to combat skilled labor shortages and solve production challenges.

Digital twins: This technology was featured for creating virtual representations of production lines, allowing for the simulation and optimization of manufacturing processes before physical implementation.

Predictive maintenance: Advanced sensor technology and cloud applications enable the real-time monitoring of machinery, allowing for predictive maintenance that reduces unplanned downtime.

Digital Product Passports (DPP): In response to EU regulations, new technologies were presented to support the implementation of Digital Product Passports, which provide information on a product's raw materials, production processes, and recycling paths. 

New and advanced materials

Sustainable polycarbonates: Covestro showcased its Makrolon® RE and Makrolon® RP polycarbonates, which incorporate recycled content or are based on renewable raw materials. These were used in applications ranging from electronics to medical devices.

Bio-based alternatives: The Fraunhofer Institute presented a new helmet made from bio-based polylactide (PLA), offering comparable protection to conventional helmets with a two-thirds reduction in CO2 emissions. Expanded PLA (EPLA) was also shown as a sustainable alternative to EPS foam.

High-performance materials for e-mobility: Complex busbars: Syensqo collaborated with Clayens to present a 360-degree approach for developing complex busbars for electric vehicles. 

Recycled polyamide: RadiciGroup received an award for a battery module made from its recycled Renycle polyamide. 

New polymer distribution companies: Omya's polymer distribution business made its official debut as the newly formed Omya Performance Polymer Distribution at the K Fair 2025 in Düsseldorf. The company showcased its portfolio of specialty polymers, innovations, and solutions for the plastics industry.  

Machinery and equipment enhancements

Manufacturers introduced new and improved machinery that was faster, more efficient, and better integrated with digital systems. 

First all-electric, tie-bar-less injection molding machine: ENGEL unveiled the new victory electric, its first all-electric, tie-bar-less injection molding machine, which combines their electric drive technology with their tie-bar-less design for increased efficiency and precision. The new machine is a world premiere that focuses on design advancements to meet specific customer requirements for greater benefits.  

Smaller, faster machines: KraussMaffei introduced a process that compounds glass fiber rovings directly in the injection molding unit to reduce material costs. Netstal showcased its new-generation Elion MED series for medical technology, known for its speed and precision.

Simplified tool changeovers: Guill Tool & Engineering introduced its Cam-Lock system, designed to simplify tool changeovers on its extrusion heads.

Upgraded extrusion lines: Brückner presented its Greenline concept for film stretching lines, a new system for high-performance films, featuring a digital standard interface. 

And of course, one of the true highlights: reconnecting with old friends and colleagues from across the plastics industry—the K Fair always feels like a family reunion!

Thanks for reading & #findoutaboutplastics

Greetings,

Herwig Juster

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Literature: 

[1] https://en.kunststoffe.de/k-fair#:~:text=Increase%20in%20Exhibitors%20at%20K,Fast%2C%20Precise%20and%20Reliable

[2] https://solutions.covestro.com/en/digital-event-space/kfair

[3] https://www.specialchem.com/plastics/news/syensqo-to-showcase-high-performance-polymers-portfolio-at-k-2025#:~:text=Syensqo%20will%20make%20its%20first,15th%20in%20D%C3%BCsseldorf%2C%20Germany.

[4] https://www.plastech.biz/en/news/Syensqo-to-debut-at-K-2025-with-specialty-polymers-portfolio-21142#:~:text=Partnerships%20and%20live%20program%20at,for%20single%2Duse%20surgical%20instruments

[5] https://www.k-online.com/#:~:text=K%202025%20focuses%20on%20key,be%20returned%20directly%20on%20site.

[6] https://www.omya.com/en/industries/polymers/events/omya-at-k-show-2025#:~:text=Recently%20founded%20Omya%20Performance%20Polymers,the%20regional%20leadership%20team%20(bios)

My Material Insights From The K Fair 2019



In the past two weeks in October the famous K Fair, the world’s number 1 fair for plastics and rubber took place in Düsseldorf, Germany.

I visited the K fair too and in this blog post I highlight the new material developments and launches of the major plastic manufacturers including new compounds as well.

Let’s start in alphabetic order:

Akro Plastic:

Akro Plastic presented new PPA compounds based on homopolymer 9T (Akromid T9). This 9T based PPA has lower water absorption in comparison with PA 6T.

Furthermore, it shows a better flowability and faster crystallization. In addition, they presented with Akromid B28 LGF40 a long glass fiber product which chemically couples PA6 and PP to a blend which enables better flow compared to pure PA 6. It has a higher conditioned strength compared to PA 6 glass fiber 50% compound.

BASF:

BASF highlighted aside of electrification of automotive industry also the fuel cell powertrain as a future mobility concept. They showed a media distribution system which was a joint project with Joma-Polytec GmbH and Mercedes-Benz Fuel Cell GmbH. BASF developed two tailor-made PA 6.6, i.e. Ultramid® A3WG10 CR and A3EG7 EQ. These grades are used now to make anode- and cathode-end plates in the fuel cell stack. Here, the purity of the material is extremely important, especially in the media distribution plate and water separator unit, where materials are exposed to cooling water, air and hydrogen.

Apart of fuel cells, BASF showed their advances in the so-called ChemCycling project, which aims at utilizing the pyrolysis oil obtained from mixed plastic waste for new polymer generation. As a result, they have now Ultramid® B3WG6 Cycled Black 00564. The latter can be used for front-end carriers in automotive.

Borealis:

Borealis introduced their new plastics recycling technology called Borcycle. The major grade named Borcycle MF1981SY, filled with 10% talc, contains more than 80% recycled polyolefins. Visible appliance applications are in the focus of use for this material. Borcycle claims to fulfill the stiffness and impact requirements needed in such applications.

DSM:

DSM launched bio-based grades of their Arnitel® thermoplastic copolyester (TPC) and Stanyl® PA 4.6, which use 25-42% bio-based feedstock. Bio-based Stanyl® grades have already the globally recognized sustainability certification ISCC Plus.

Furthermore, DSM offers now Akulon RePurposed PA. This polyamide contains recycled nylon-based fish nets.

DuPont:

DuPont presented their Zytel long chain nylon 6.12 for blow moulded cooling pipes. It is a technology that can be transferred to electric cars and gains traction there.

EMS Chemie:

EMS presented their new grades of Grilamid TR: XE 11248 and FE 11292. These are both transparent high-performance polyamides especially developed for the medical application market. Grilamid TR XE 11248 has high flexural strength and improved alcohol resistance. Grilamid TR FE 11292 can be sterilized with steam over hundreds of cycles and can be used in combination with silicon (LSR).

Further highlight was the use of Grivory G5V and Grivory HT6 for advanced metal replacement. Grivory HT6 shows a 50% higher stiffness at 140°C compared to standard PPA.

Evonik:

Evonik increases their Vestamid® PA 12 capacity by over 50% between 2019 and 2021, which shows the commitment to capture more market, especially in the automotive tubing market.

Lanxess:

Lanxess communicated that it is collaborating with artificial intelligence company Citrine Information to apply AI in the development of customized plastics. They see glass fiber sizing customization a way to cut down the time to market. For high voltage connectors in electric vehicles, Lanxess offers now UL yellow card certified orange (RAL 2003) PA and PBT compounds.

Polyplastics:

Polyplastics presented their new Durafide® PPS grade entitled 6150T73 which has outstanding heat shock resistance and high mouldability. This grade addresses the need of having resins which can be used for overmoulding metal parts in automotive power control units (mainly electric cars) and withstand harsh automotive environments (-40°C/ +150°C). Furthermore, they introduced WW-09, which is a new Duracom® POM grade. It combines high strength with good creep and sliding properties.

Sabic:

Sabic unveiled their Lexan® polycarbonate based on certified renewable feedstock. PC is part of their Trucircle circular solution and allows customers to reduce CO2 emissions.

Solvay:

Solvay launched a new high Tg PEEK called Ketaspire® PEEK XT. Solvay belongs to the group of material suppliers bringing a new polymer to the market place. It has exceptional chemical resistance with a 20°C higher glass transition temperature compared to standard PEEK. There are already polyketones which have a similar high Tg, however their chemical resistance is lower than the Ketaspire® XT. The XT portfolio covers neat resins (XT-920), glass fiber reinforced compounds (XT-920 GF30), and carbon-fiber reinforced compounds (XT-920 CF30).

Additionally, Solvay launched a PPA-based unidirectional (UD) thermoplastic carbon fiber-based tape to accelerate thermoplastic composite developments in automotive industry.

Their third launch was the new long glass fiber portfolio called Xencor™, which covers PA 6.6., HPPA, PPA, PARA, and PPS long glass fiber products. Xencor™ polyarylamide PARA was selected by Monaco-based Stajvelo to make an all-polymer electric bike. The material fulfills the high structural, mechanical, and aesthetic requirements.

Victrex:

Victrex presented their Victrex HPG™ Gear solutions for powertrain applications. These have good NVH and durability performance. In addition, they announced that their manufacturing facility in Grantsburg, USA, received the IATF 16949 certification. This certification proves that all capabilities are in line with Tier-1 and OEM needs.

What were your experiences on the K fair?

Thanks for reading & till next time!

Greetings,

Herwig Juster

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