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

📚My Polymer Material Selection Book - Available Here

📊 Discover your Polymer Material Selection score by taking quick test here

🎥Join my YouTube channel community 

🔎Join my inner circle (monthly newsletter)

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 new book "How to innovate when you must. A practical guide on unlocking innovation" - now available worldwide on Amazon.com

Today I am introducing to you my new book, How to innovate when you must! 

"How to innovate when you must" by Herwig Juster - now worldwide available. 

Why innovation is crucial, especially during economic crises

I believe that innovation is not a luxury, but a necessity, especially during economic downturns. Economic crises force businesses to adapt and evolve. Those that embrace innovation thrive, while those that resist often falter. 

Here are five reasons why innovation is paramount during these challenging times:

1. Competitive Advantage:

• Differentiation: Innovation allows businesses to stand out from competitors by offering unique products or services.
• Market Leadership: Pioneering new solutions can position a company as a market leader.

2. Customer Satisfaction:

• Enhanced Value: Innovative products and services can provide greater value to customers.
• Loyalty: Satisfied customers become loyal advocates, driving future growth.

3. Cost Reduction:

• Efficiency: Innovative processes and technologies can streamline operations and reduce costs.
• Resource Optimization: By finding new ways to use resources, businesses can save money.

4. Risk Mitigation:

• Agility: Innovative companies are better equipped to adapt to changing market conditions.
• Resilience: By diversifying offerings or entering new markets, businesses can reduce their reliance on a single revenue stream.

5. Long-Term Growth:

• New Opportunities: Innovation can uncover new markets and revenue streams.
• Future-Proofing: By investing in innovation, businesses can position themselves for future success.

Innovation is not just a buzzword; it's a strategic imperative. By embracing innovation, businesses can not only survive economic downturns but emerge stronger and more resilient.

How to embrace innovation - Get ready to rethink innovation

This brings me to my new book. It is a comprehensive guide which offers 15 actionable strategies to ignite creativity, spark new ideas, and drive business growth. Through a step-by-step approach, you will learn how to identify untapped opportunities, cultivate a supportive environment, and implement innovative solutions that deliver tangible results. 

Additionally, the included innovation readiness assessment will help you pinpoint your organization's current innovation maturity and guide you toward a more innovative future.

Ready to revolutionize innovation in your organization? My new book, How to innovate when you must, is your guide.

It is my first book outside core polymer engineering topics, however can be perfectly applied to plastics industry organizations, helping to foster new ideas and business growth. If you get a copy, please let me know what you think. You can send your comments either directly to me, or leave a review on the Amazon.com.

Join the innovation revolution! Grab your copy here and let's shape the future.

Thanks for reading & #findoutaboutplastics

Greetings, 

Herwig 

Prejudices Against Plastics - A Break on Innovations? Expert Interview Video Series with Dirk Moses - Technoform & Herwig Juster FindOutAboutPlastics.com (Part 3/3)

Part 3 of our expert talk with Dirk Moses from Technoform.

Hello and welcome to this polymer expert interview series with Dirk from Technoform, diving into the world of sustainable polymer solutions. 

It is a three part video series and today we continue with the third and last part:

💡 Prejudices Against Plastics - A Break on Innovations?💡

In this video, we get to the bottom of the prejudices against plastics and reveal the truth behind the negative headlines. 

Dirk and his team at Technoform talk about the unfair bias that the plastics industry has experienced in recent years.

Despite the widespread assumption that plastics are a bad choice for the environment, data reveals a different reality: 'Plastics make up only a tiny fraction of the materials used worldwide and therefore contribute minimally to the carbon footprint. In contrast, other materials such as cement, metal, ceramics and concrete cause the majority of CO2 emissions'.

We discuss the various aspects of the carbon footprint of plastics and emphasize the importance of taking a holistic view of the manufacturing process and the service life of products. We show how plastics can make a positive contribution to the environment through their longevity and efficiency in disposal.

Despite the challenges and the long time it sometimes takes for innovative plastic solutions to be accepted by customers, Dirk and his team are optimistic about the future. 

They have already developed successful plastic solutions for cooling battery systems and see an increased focus on recycling and sustainability as future trends. Also, Dirk sees the future of polymer-based solutions as indispensable, especially in areas such as technical components, packaging and transport as well as construction materials. Plastics offer unique properties such as design flexibility, thermal insulation, mouldability and chemical resistance, which make them irreplaceable for many applications.

Watch the video below or here. The Podcast version can be found here.

Check out the other two interviews too:

Part 1: Plastics & Sustainability - A Contradiction?

Part 2: Sustainable Plastics Solutions For The Automotive Sector

Get in touch with Technoform here. 

Thanks for reading & watching!

Greetings, 

Herwig 

📚My Polymer Material Selection Book - Available Here

📊 Discover your Polymer Material Selection score by taking quick test here

🎥Join my YouTube channel community 

🔎Join my inner circle (monthly newsletter)

Plastics & Sustainability - A Contradiction? Expert Interview Video Series with Dirk Moses - Technoform & Herwig Juster FindOutAboutPlastics.com (Part 1/3)

Expert interview with Dirk Moses from Technoform: Plastics & Sustainability - a contradiction?

Hello and welcome to this polymer expert interview series diving into the world of sustainable polymer solutions. It is a three part video series and today we start with our first video:

🌱 Plastics & sustainability - a contradiction? 🌱

I visited Technoform in Lohfelden, Germany to explore the link between plastics & sustainability. In this video I find out how Technoform has been researching sustainable solutions since 2015, from the use of renewable resources to the introduction of innovative separation technologies. Dirk Moses and his team are setting standards, from overcoming skepticism about bio-based materials to making effective use of production waste.

Since the Sustainable Development Goals were set in 2015, Technoform, solution provider for customized plastic profiles, has been exploring measures to enable sustainable plastic solutions. 

From the use of renewable resources to the introduction of innovative separation technologies along the value chain.

We learn how Technoform has tackled the challenges of the thermoplastic market, from initial scepticism towards bio-based materials to the effective use of production waste and the development of single-variety recycling methods. These strategies not only have an environmental impact, but also contribute to the quality of the products.

Dirk Moses and his team are committed to avoiding production waste and are working on solutions to save resources and reduce environmental impact. 

By utilizing post-industrial plastics and calculating the CO2 equivalents of their raw materials, they are leading the way in the industry and helping to shape a sustainable future.

Get an insight into the world of plastics innovation and discover how Technoform and companies can make an important contribution to conserving our resources while improving the quality of their products.

Watch the video now here:

Stay tuned for two more episodes:

- Sustainable plastics solutions for the automotive sector

- Prejudices about plastics - a brake on innovation?

Get in touch with Technoform here. 

Thanks for reading & watching!

Greetings, 

Herwig 

📚My Polymer Material Selection Book - Available Here

📊 Discover your Polymer Material Selection score by taking quick test here

🎥Join my YouTube channel community 

🔎Join my inner circle (monthly newsletter)

Shu-Ha-Ri: An essay on innovation in plastics industry

The new economy is disrupting one industry after the other. With its customers being disrupted the plastics industry is no exception. Industries are pushed to adapt and in many cases even shift their core competencies in order to survive. A case in point is the ongoing shift from combustion engine expertise to battery technology expertise in the automotive industry [1]. Every disruption brings along opportunities for implementing new plastic solutions.

What are the ways in which a business organization must change to take up hard problems and offer unique solutions in a VUCA (Volatile, Uncertain, Complex and Ambiguous) world? First, business development must be customer-focused, i.e., customer is the center for innovation. This means a paradigm shift from market push to customer pull is necessary. Secondly, innovation concepts must be pre-defined. Only in this way, organizations can work effectively toward it.

Shu-Ha-Ri is a Japanese concept used in martial arts [2]. In my opinion, this may be applied in the context of innovation as well and help us to gain ground in the new economy environment. Following, I will explain the concept of Shu-Ha-Ri at first through a cooking example [1, 2]. Thereafter, I will make the bridge from the mentioned example to the plastics industry.

Shu ("protect", "obey"): This is the beginner’s stage. In this stage, you start cooking according to the recipe and you keep yourself strictly to the recipe. There are no modifications. Convenience food manufacturers and fast food services are in those categories as industrial examples.

Translation to the plastics industry: For instances, concerning injection moulding: the machine operator is acquainted with the machine and the handling of the moulding process. The focus is mainly on how to excel the task in a mechanistic manner, e.g. proper injection moulding of thermoplastic resins.

 

Ha ("detach", "digress"): At this level, you still follow the recipe for cooking, but you start adding your sense of flavor. This can mean that you add a bit more salt and pepper to better fit the taste of the whole meal.

Translation to the plastics industry: The above-described machine operator starts learning the underlying principles behind the injection moulding process and is able to combine knowledge from the three M’s in plastics processing: Material, Machine and Mould. As a result, he/she is able to set up and adjust the running process.

 

Ri ("leave", "separate"): This is basically reinventing the way you cook a certain meal or even one step further to invent complete new ways of making new meals. To put it simple, with Ri you are the rule and you are able to seek unique solutions to hard problems or re-invent the way we do things. Translation to the plastics industry: The machine operator starts creating his/her own ways of processing and incorporates that in his/her daily operations. 

Shu-Ha-Ri in plastics industry:

The basic idea is that people in a (plastics) technology organization have to go through the different stages of Shu-Ha-Ri to be able to achieve excellence in innovation. Their mind- and skills set need to reach the Ri-level.

For too long, the majority of big companies shaped their departments toward Shu. This resulted in process thinking, performance self-assessment and outsourcing of services. Several departments made themselves redundant, which is highly beneficial for commodity type of business. Reduction of costs is the major upside of such systems, while major downsides include brain and skill drain. Because core competencies were more and more outsourced to Tiers [2], organizations struggle now to bring Ri-type of innovations to the market.

Now, in the times of new economy, we need more Ri skillset to integrate software, hardware and design into excellent products. The expectation of business leadership to transform Shu level stuff (‘cooking according the recipe’) to Ri innovators (‘re-invent the way of cooking’) has several challenges. Take plastic resin formulation as an example: Changing a resin formulation will result in Shu- and Ha-type of innovation. The base feedstocks are well known and available mostly in huge quantities. Exchanging certain parts of the recipe can, thus save costs.   There is no new market, nor new product involved. Conversely, for Ri-innovation, the business outcome is not clearly defined, meaning that there is no business case where you can be 200% sure that the numbers will be hit. This means that people need to have more an entrepreneurial edge then a classic business economics background. In Shu and Ha, business cases make sense and are accurate, since experience exist (from R&D, procurement over to supply chain). This is the reason why this way of “innovation” is preferred, resulting in efficiency innovation (e.g. moving production to cheaper locations) and good enough downgrade innovations (e.g. hardcover book to paperback only).


I would like to end this post with an example in plastics business, which shows a Ri behavior:
The 3M Company implemented a three-step process [3], which ensured them fruitful innovations over the years. The designated functions of the steps are “Scouts,” “Entrepreneurs” and “Implementers”. The scouts are the project hunters. Their job is to identify hard problems which are worth solving. The Entrepreneurs help then to figure out how to capitalize on the opportunities. Those can be manufacturing experts, engineering and other functional experts. They carve out a functional prototype. Once all the product related investigations are done, Implementers take over. Their job is to get the new product ready for commercialization. Scouts, Entrepreneurs and Implementers have a strong Ri-mindset and are able to think outside the classic ways because they know that is the only way to solve hard problems! It is a step away of ‘what’s in it for me’ and focusing on the greater vision of improving everyone’s life.

Thank you for reading and successful innovating!
Greetings,

Herwig

P.S. New to my blog – check out the start here section

Literature:

 [1] Prof. Dr. Gunter Dueck – Der Prozess ist der Innovation ihr Tod, Podcast Markenrebell, June 2017

[2] https://martinfowler.com/bliki/ShuHaRi.html

[3] https://www.fastcompany.com/40437745/the-three-step-process-thats-kept-3m-innovative-for-decades