Guidelines Promote Confidence in Mass Balance for Sustainable Plastics Use
The EU Commission has released new proposals supporting the use of mass balance for chemical recycling, adopting a fuel-exempt accounting approach under the Single Use Plastics Directive (SUPD). The Commission emphasized that “the calculation methodology will serve as a model for future recycled content rules in other sectors, such as packaging, automotives and textiles. This approach is designed to give investors’ confidence in the long-term stability and potential of these technologies.
Mass-balance acceptance is regarded as a critical facilitator for chemical recycling – most notably pyrolysis oil, since pyrolysis oil acts as a naphtha replacement in crackers. Uncertainty about regulation has witnessed demand from the chemical industry for pyrolysis oil decline during 2024 and 2025 (though from a high level) and rendered financing for new projects and infrastructure problematic.
Varying accounting principles for mass balance can significantly change possible profitability, and a lack of transparency has made it difficult to forecast returns on investment, as well as determine Europe’s relative competitiveness vis-à-vis other areas likely to follow varying mass-balance accounting principles.
The EU Commission has launched a consultation on the proposals, which also covers the calculation, verification and reporting of recycled content under the SUPD. The consultation will run until 19 August. The Commission will then conduct a review before presenting a final draft to its technical committee to vote on.
It aims to adopt the proposals under an implementing decision in Autumn 2025. Previously, the EU Commission had said that it was aiming to adopt the implementing decision in the fourth quarter of 2025.
Under the proposal, the EU will adopt “fuel-use excluded” mass-balance accounting, whereby material that is processed into fuel or process losses cannot contribute to recycled content targets. Free allocation (a method of mass balance that allows for the total allotment of recycled material to be attributed to any output) would be permissible for the remaining tonnage. This is provided that:
It is only attributed to outputs where it is possible to prove there is a feasible chemical process that could transform the input material into the chemical building blocks for each output
The attributed amount of a specific output does not exceed the share of those parts of the output that can come from the used input eligible material
The inputs, outputs, or both are chemical building blocks but not polymers.
This would also apply to dual-use material – material that can be used in both fuel and non-fuel applications – in liquid or gas form. Solid material such as char would be excluded from the calculations.
The Commission considers that “mechanical recycling technologies are in general preferable to chemical recycling technologies from an environmental point of view” and states that material that can be mechanically recyclable should not be used by chemical recyclers where it can produce recyclates with similar quality or performance characteristics. As a result, the proposals include allowances for the Commission to review the methodology and allocation rules under the decision.
For liquid inputs fed into a steam cracker, the calculation steps to determine the allocation volume of recycled material would involve defining the maximum allowable boiling point at the steam cracker (or where the eligible material is processed by different steam crackers, the weighted average of the maximum acceptable boiling points of all the individual steam crackers), measuring the evaporation between eligible input material and total input material, calculating the ratio between the two and then applying that ratio to the total input weight at the cracker. This would involve using a standard test method for boiling range distribution of petroleum fractions by gas chromatography.
For non-liquid material or processes not involving steam cracking, material would be distributed proportionally based on share of total input. For dual-use outputs, evidence would be required to prove that the material is being used in recycled plastics.
The new implementing decision and annex does not appear to give any further clarity on the use of imported material counting towards the 25% recycled content required in polyethylene terephthalate (PET) beverage bottles from 1 January 2025.
ICIS published an article in June following confirmation from the European Commission that only recycled polyethylene terephthalate (R-PET) produced using plastic waste in the EU can currently count towards the 25% recycled content target set out under the SUPD.
However, following publication, market participants challenged this statement from the Commission’s Directorate-General for Environment highlighting the use of the word “imported” in formulas contained in the Implementing Decision annexes, which those participants understood allowed the use of R-PET flake and food-grade pellet from third countries outside the EU to count towards the target.
Imported material is still mentioned in the draft annex and ICIS is currently seeking further clarification from the Directorate-General for Environment over the status of imported material in counting towards the 25% target.
Climate Action and Resource Efficiency Emphasized in Latest Sustainability Filing
With a major step toward moving closer to promoting transparency, accountability, and sustainable development, Molecor formally presented its yearly Communication on Progress (CoP) to the United Nations Global Compact, affirming its longstanding belief in doing business responsibly. Being a signatory to the Global Compact, Molecor is part of the global network of thousands of companies that work in alignment with the Ten Principles of the initiative, which include human rights, labor, environment, and anti-corruption, while also supporting the attainment of the UN Sustainable Development Goals (SDGs).
Photo Credit: Molecor
The CoP report, now presented in a revamped digital questionnaire format as part of the UN Global Compact’s enhanced reporting framework, enables companies to offer more structured and standardized data. This new format not only simplifies the process of tracking progress but also significantly improves the visibility and comparability of corporate performance across sectors and geographies. Molecor’s responses in this report provide tangible evidence of its dedication to integrating sustainability into its core operations and long-term strategic vision.
As part of the filing, Ignacio Muñoz, CEO of Molecor, released an official declaration reaffirming unconditional commitment to the UN Global Compact and recommitting to staying true to its principles. “Our membership in the UN Global Compact is not just formal—it is a guiding principle on how we do business responsibly, ethically, and sustainably,” Muñoz underscored. His message, together with the extensive CoP submission, is now publicly available on the UN Global Compact website, highlighting Molecor’s commitment to acting in absolute transparency and integrity.
As an added gesture beyond the requirements, Molecor also voluntarily made available its latest Non-Financial Information Statement (NFIS). This supplementary document provides a comprehensive account of the company’s environmental, social, and governance (ESG) performance. It outlines the firm’s sustainability metrics, carbon footprint management strategy, supply chain due diligence, gender equality measures, circular economy strategies, and decarbonization initiatives in the water infrastructure and plastics industries—where Molecor is a technological pioneer in manufacturing oriented PVC (PVC-O) pipes.
The NFIS adds value to the Communication on Progress by providing stakeholders, investors, regulators, and the public a comprehensive view of Molecor’s sustainability pathway. This is a responsible, proactive stance by Molecor, grounded in the belief that non-financial performance and footprint is as important—and in most cases more meaningful—than a company’s financial performance, as today’s global economy calls upon stakeholders to hold corporations accountable beyond numbers, but to demonstrated impact.
Importantly, Molecor’s practices are in-line with the European Union (EU) Corporate Sustainability Reporting Directive (CSRD) and the Global Reporting Initiative (GRI) standards for sustainability performance, meaning the company is reinforcing its sustainability governance while better preparing themselves to meet reflections of new regulatory expectations.
Molecor publicly declared its progress and voluntarily went beyond the statutory minimum requirements for reporting on favourable outcomes for itself. This has once again reiterated Molecor’s leadership in innovation for sustainability, specifically in respect of water management infrastructure. Its technology assists with reduces water loss and energy use across networks globally, especially in water-scarce areas, which is tackling a major pressing issue, in keeping with, among other SDGs, SDG 6: Clean Water and Sanitation, and SDG 13: Climate Action objectives.
The detailed reporting of favourable outcomes reinforces Molecor’s sustainable innovation and responsibility-driven governance philosophy and confirmed it as a global authority across the circular economy of plastic-based infrastructure solutions for global water management. Given the many concurrent, intensifying environmental and social challenges we are currently facing, Molecor’s disclosures are an example of how businesses demonstrate their role in potentially managing related and existing environmental and social challenges towards a just, resilient, equitable and sustainable future.
Advanced ESD Solution Introduced to Tackle Packaging Challenges in Electronics
The Electrostatic Discharge (ESD) Plastic Sheet (PET), a specially designed solution created to meet the vital requirements of India’s quickly growing electronics and device manufacturing ecosystem, has been introduced by Cosmo Plastech, the rigid packaging division of Cosmo Films, a world leader in specialty films.
Higher quality and dependable packaging solutions are essential as India solidifies its position as a global center for electronics production, driven by initiatives like “Make in India” and rising domestic demand for semiconductors, cellphones, and other electronic components. Furthermore, the need for ESD-safe materials is expected to rise sharply as the electronic packaging industry experiences growth. Cosmo Plastech’s PET-based ESD sheet is both required and relevant in light of this ongoing development.
The newly developed ESD Plastic Sheet (PET) is designed to manage and dissipate static electricity efficiently in order to prevent damage to electronic components while they are stored, handled, and shipped. Produced keeping in mind the word class standards of quality and environment, the PET sheet is RoHS compliant, conductive, and dissipative in nature, and is antistatic. The ESD sheet also adheres to cleanroom needs through its dust-free, recyclable material, providing customers, both function and eco-friendliness in a single product.
Cosmo Plastech’s ESD sheet is ideal for IC and chip trays, cell phone and component manufacturing trays, and general-purpose material handling trays. The sheet therefore brings added protection and efficiency to the electronics industry. Not only does it safeguard electronic components and devices, but also streamlines packaging operations in ESD-sensitive environments.
Commenting on the launch, Mr. Himanshu Gupta, Business Head (Rigid Packaging), Cosmo First said, “India’s electronics sector is witnessing a transformative phase, and packaging has a key role to play in protecting the heart of this revolution which is its components. With our ESD PET sheet, we are not just offering a material, we are also offering assurance, safety, and innovation to a sector that is powering India’s technological growth.”
With the packaging industry for electronics set to boom, product innovations such as Cosmo Plastech’s ESD PET sheet are going to be a key offering in protecting the functionality and quality of valuable electronic products. By leveraging unique designing capabilities and decades of sector experience, Cosmo Plastech aims to deliver immense value by facilitating the safe transportation and storage of vital components that drive the digital economy.
Cosmo Plastech’s PET-based ESD sheet further solidifies the brand’s position as a reliable and trusted partner in the rigid packaging industry, helping shape the landscape of electronics manufacturing with forward-thinking, high-performance packaging solutions.
Thermal Runaway Event Simulation Project Seeks Safer Energy Storage Designs
In response to the growing importance of thermal management and fire protection in electromobility, AZL Aachen GmbH is launching a new Joint Partner Project entitled “Thermal Runaway Testing for Battery Casings – Benchmarking Systems for High-Gradient Heating and Hot Particle Blasting.” This initiative focuses on developing and implementing a realistic and reproducible fire testing environment for structural and functional materials used in EV battery housing systems.
Advanced Testing Infrastructure for Real-World Conditions
The project centers around the development and implementation of a new test bench that combines high- gradient flame exposure and controlled hot particle impact – mimicking the complex conditions of thermal runaway events in modern cell technologies such as LFP and NMC. This setup enables systematic benchmarking of materials under stress conditions that reflect actual applications in automotive, but also in other segments like aerospace, where efficient development of safe battery storage systems is essential. Participating companies will not only have access to the final benchmarking results but can also contribute material configurations for testing as part of the project.
Benchmarking Materials and Defining Safety Profiles
Through tailored test profiles, thermal resistance and mechanical integrity of different materials will be compared based on application-specific scenarios. Detailed test documentation, including videos and thermal data, will be provided. The resulting matrix supports materials development, qualification, and supplier evaluation, offering both strategic and technical value.
A Collaborative Approach to a Shared Challenge
Within a predecessor collaboration involving a consortium of 24 leading industry players (including automotive OEMs like Audi, BMW, Tier suppliers, and material producers), AZL ́s team of experts developed an application relevant instrumented test method that allows testing of materials at different flame temperatures and simultaneously measuring the material strength under fire load. In the project more than 50 different materials (metals, plastics, fibre reinforced, coated, compact, sandwich) were tested and benchmarked regarding their specific performance (survival at tensile load and 800, 1000, 1200 °C flame exposure; failure; areal weight; cost per area). The new Joint Partner Project builds on these results, know-how and test infrastructure implemented. It enables participants to pool resources, validate their own solutions, and gain insight into leading alternatives in the market. With more than ten years of experience managing collaborative industry projects, AZL ensures a professional and transparent execution with clear, practical outcomes.
The project will officially kick off on July 15th, 2025. At the initial meeting, partners will align on expectations, present their priorities, and help refine the testing focus. Companies interested in joining are encouraged to request detailed project information or arrange an individual consultation meeting:
Immunoassay Reliability Strengthened with Latest Synthetic Polymer Launch
The Sciforiem PL 1000 Series of functional synthetic polymers will be introduced to markets outside of Japan starting in July by Artience Co., Ltd., the holding company for the Tokyo-based chemicals manufacturing organization Artience organization. Sciforiem polymers are useful for the creation of biosensors, diagnostic tests, and other in vitro diagnostic (IVD) systems because they can be designed to mimic biological processes and are produced from non-biological raw ingredients.
Medical devices called IVDs are used to detect illnesses by analyzing biological samples, such as tissue or blood. Sciforiem PL 1000 polymers are specifically tailored for use in IVDs that detect target molecules by means of antigen-antibody reactions. These polymers can improve the overall performance of the reagent by stabilizing proteins, increasing detection sensitivity, and preventing non-specific protein adsorption when applied to the substrate material in antigen-antibody reaction detection.
Such biological functions performed by Sciforiem polymers are useful in various applications, such as blocking agents in immunoassays like ELISA and immunochromatography or as protein stabilizers in IVD assays. In biomolecule research, they act as additives in diagnostic reagents due to their ability to enhance functionality and stability.
With a century-plus heritage rooted in printing ink innovation, artience is uniquely positioned to apply its cutting-edge technologies, which have been honed over the decades, to engineer polymer products that address the stringent quality standards of today’s medical, electronics and other high-end fields. “Historically, bio raw materials were considered a biomanufacturing challenge for their inconsistent quality,” said Nozomu Hatano, General Manager of artience ‘s Biotech Business Unit in Japan. “By adopting artience ’s polymer design and dispersion technologies to address stability issues in raw materials, our engineers were able to fabricate a functional polymer for in vitro diagnostic reagents that exhibit minimal variation in quality. We expect the new Sciforiem PL 1000 Series to significantly reduce diagnostic errors and improve patient care, going forward.”
The Sciforiem Series of life science products from artience will be making its global debut at ADLM 2025 (or ADLM Annual Scientific Meeting & Clinical Lab Expo), in Chicago, from July 27 to 31, 2025. In addition to functional synthetic polymers, artience will be featuring the Sciforiem FI Series of near-infrared (NIR) fluorescence probes for high-sensitivity imaging.
Creating New Opportunities for Growth in Cambodia’s Printing, Packaging, and Plastics Sectors
When the Cambodia International Plastics, Printing & Packaging (PPP) Industry Fair opens its doors from August 6th to 9th, 2025, it will mark more than just another trade event — it will signal a renewed push for industrial modernization in one of ASEAN’s most dynamic emerging economies. Organized by Chan Chao International and Yorkers Trade & Marketing Service, in cooperation with the Cambodia Chamber of Commerce and backed by Cambodia’s Ministry of Commerce and the Korea Packaging Association, this second edition of CamboPlasPrintPack will gather local manufacturers, international suppliers, government officials, and industry thought leaders under one roof at Phnom Penh’s Diamond Island Convention and Exhibition Center. For four days, the venue will transform into a vibrant hub where business deals are struck, knowledge is exchanged, and a clearer vision for Cambodia’s industrial future comes into focus.
Cambodia’s industrial momentum has been steadily building for over a decade. Despite global headwinds and pandemic disruptions, the country’s GDP is forecast to grow by over 6% in 2025 — thanks in part to rising domestic consumption, robust foreign investment, and an ambitious push to improve logistics and infrastructure. Within this context, the plastics, printing, and packaging sectors have become vital enablers for Cambodia’s light manufacturing and export-oriented growth. As rising incomes fuel demand for consumer goods, packaged foods, electronics, and e-commerce, local businesses are under pressure to modernize their production lines and deliver cost-effective, high-quality, and increasingly sustainable packaging solutions.
For many exhibitors and visitors alike, the 2025 fair could not come at a better time. The show is expected to attract upwards of 8,000 qualified trade visitors, from brand owners and distributors to converters and machinery buyers. In addition to the main event, it will run concurrently with the Cambodia International Textile & Apparel Accessories Exhibition, creating valuable cross-industry synergies. Attendees will have the opportunity to explore a vast array of solutions, from high-speed extrusion lines and blow molding machines to advanced flexographic and digital printing systems, biodegradable packaging innovations, and smart labeling technologies. Live demonstrations will help local manufacturers see these systems in action — an invaluable experience for decision-makers who still rely heavily on traditional processes.
What makes the Cambodia PPP Industry Fair especially significant is that it’s not just about selling equipment. It’s about plugging Cambodian businesses into a broader regional value chain and equipping them with the tools to compete. Over the past few years, Cambodia has stepped up its commitment to public-private partnerships (PPPs), aiming to deliver major infrastructure improvements — from the new Phnom Penh–Sihanoukville expressway to energy plants and the headline-grabbing Funan Techo Canal project. The canal alone, set to be the country’s largest infrastructure project to date, will link Phnom Penh to the Gulf of Thailand and the South China Sea, dramatically reducing transport costs for inland manufacturers and exporters. Such developments hold the promise of making Cambodia not only more self-sufficient but also better connected to the region’s supply chains.
However, infrastructure alone isn’t enough. To capitalize on these improvements, local manufacturers need advanced machinery and technical know-how. This is where CamboPlasPrintPack 2025 comes in. For international machinery suppliers, Cambodia remains a relatively untapped market with enormous potential. For Cambodian companies, the fair offers a chance to discover technologies that can help them reduce production costs, meet export standards, and pivot towards more sustainable business models. The push for sustainability is especially important: as ASEAN countries tighten regulations on single-use plastics and introduce circular economy initiatives, local producers are eager to learn about biodegradable materials, recycling-friendly designs, and ways to minimize waste in production.
Another key element of the fair will be the structured networking and business matching services provided by the organizers. With support from the Ministry of Industry, Science, Technology and Innovation (MISTI) and the Korea Packaging Association (KOPA), the event will host technical seminars and panel discussions where industry veterans can share insights on topics like risk management, regulatory trends, packaging design innovation, and new export opportunities. Such knowledge-sharing is vital for small and medium-sized enterprises (SMEs) that make up the bulk of Cambodia’s industrial base. Many still face challenges related to limited technical capacity, supply chain disruptions, and a lack of clear pathways for sustainable growth.
For exhibitors, the benefits go far beyond the event’s four days. Each company gains exposure through the official show catalog, ensuring their brands remain visible to buyers and partners well after the fair ends. This marketing boost is invaluable, given Cambodia’s highly competitive yet still-maturing industrial sector. It is precisely this blend of opportunities — real business leads, sector insights, and relationship building — that makes CamboPlasPrintPack a must-attend for stakeholders serious about tapping into Cambodia’s growth story.
All of this unfolds within a bigger regional narrative: Southeast Asia’s ongoing shift toward becoming a diversified manufacturing powerhouse. With production costs rising in traditional strongholds like China and Thailand, Cambodia’s strategic location, open trade policies, dollarized economy, and young workforce offer an attractive alternative for investors looking to hedge supply chain risks and expand capacity. Events like the Cambodia International Plastics, Printing & Packaging Industry Fair provide the platform to translate these macroeconomic advantages into tangible deals and long-term partnerships.
Ultimately, success for the 2025 edition won’t just be measured by the number of booths filled or the footfall on the exhibition floor. It will be judged by whether Cambodian manufacturers find the solutions they need to upgrade their operations, whether sustainable technologies take root, and whether meaningful connections form between local and international players. In a world where industrial competitiveness depends as much on collaboration and knowledge transfer as on machines and raw materials, CamboPlasPrintPack 2025 represents a critical bridge between ambition and action.
For Cambodia, the stakes are high — and the rewards could be transformative. By aligning infrastructure development, industrial upgrading, and regional partnerships under the PPP framework, Cambodia is laying the groundwork for a more resilient, diversified, and forward-looking manufacturing sector. And for everyone who walks through the doors of the Diamond Island Convention and Exhibition Center this August, the fair will offer more than a glimpse of the industry’s future. It will be a place where ideas become investments, connections become contracts, and a young industrial nation takes one more confident step onto the regional stage.
AI and Sustainability Lead Plastics Developments at K 2025
ENGEL will showcase the successful integration of technical innovation, digital intelligence, and sustainability at K 2025. The presentation at the trade show focused on industry-specific injection molding solutions that help businesses produce goods more accurately, flexibly, and efficiently. From fully integrated production cells for the automotive, medical, technical molding, and packaging industries to the application of artificial intelligence in the operating injection molding process, they will demonstrate its technologies and solutions in real-world settings. In addition to seeing the world premiere of a new electric tie-bar-less injection molding machine, visitors are welcome to visit ENGEL’s display in Düsseldorf to obtain a thorough overview of future-proof applications.
Automotive: Efficient mastery of function, lightweight design and new materials
Functionalised rear-end-lights are produced on the ENGEL duo 700 – with high precision and using clearmelt and foilmelt in a single integrated process with a compact footprint. Image source: ENGEL
Where design meets function: rear-end-light modules with clearmelt and foilmelt without hardcoating
They are demonstrating the highly integrated series production of innovative rear-end-lights on a high-performance duo 700 two-platen injection moulding machine with 7000 kN clamping force. The visible parts, measuring 600 x 240 mm, are manufactured using a combination of decorative foilmelt and functional clearmelt technologies in a vertical rotary table mould. In addition to design freedom, downstream processes are integrated into the injection moulding cell, and a separate hardcoating process is no longer required thanks to clearmelt. While the colour design from a decorative foil is applied to the component on one mould side by back-injection of thermoplastics (foilmelt), the opposite side is overflooded with polyurethane (clearmelt) to form a highly transparent and robust protective layer. A space-saving integrated automation system with a viper 40 linear robot enables short cycle times within a compact and efficient cell. The transfer foil is supplied by LEONHARD KURZ. At the partner’s stand, the component is further processed using an integrated LED function foil.
With this application, ENGEL demonstrates how visible parts in the automotive sector can be both functionalised and decorated – economically, with high precision, and in a compact production process.
Overmoulding with liquid silicone: precision seals for fuel cells
A production cell with a vertical insert 150 injection moulding machine, offering 1500 kN clamping force, demonstrates the fully automated manufacturing of liquid silicone rubber (LSR) seals on sensitive gas diffusion layers (GDL) for fuel cells. The LSR seal is applied with absolute platen parallelism directly in the machine, inspected in the mould and the component is immediately removed. The automation system, featuring ENGEL easix articulated robot and a rotary table mould supplied by ACH, ensures short cycle times and high process reliability. To save space, the control cabinet is integrated directly into the machine frame. They are showcasing a highly cost-efficient solution for fully automated overmoulding with thin LSR layers in a compact footprint.
Unveiled at K 2025: the next evolution of electric tie-bar-less injection moulding machines. Image source: ENGEL
Lightweight, strong, sustainable: bicycle handlebars with fluidmelt and organomelt
A novel bicycle handlebar is manufactured as a hollow component on a tie-bar-less ENGEL victory 180 injection moulding machine with 1800 kN clamping force. The fluidmelt process is used to create the hollow structure, while unidirectional continuous carbon fibre tapes are simultaneously integrated using the organomelt process. This innovative combination of technologies enables maximum part performance with minimal weight and a short cycle time of just one minute. The process is fully automated with an easix articulated robot. With these technologies, ENGEL once again sets new benchmarks in production efficiency and sustainability – opening up new markets for plastic components in applications traditionally dominated by metal.
Cost-efficient and ready for series production: Physically foamed B-pillar trim using MuCell
A B-pillar trim component is produced in just 50 seconds using the ENGEL foammelt technology on a t-win 6500 two-platen injection moulding machine from the WINTEC brand, part of the ENGEL Group. The foamed part, weighing 290 g, is made of mineral-filled PP from Sabic. ENGEL’s foammelt technology reduces weight and cuts material and production costs while achieving excellent surface replication. Automation is handled by a highly integrated viper 20 robot. WINTEC here demonstrates a cost-effective solution for producing visible interior automotive components.
Lightweight and robust components made from 100 % post-consumer recyclate are produced on the all-electric ENGEL e-mac 220 – with up to 50 % less scrap thanks to ENGEL iQ weight control. Image source: ENGEL
High-precision manufacturing for medical products: Cell culture plates with accelerated validation
In the Medical area, ENGEL showcases a highly efficient injection moulding cell built around an all- electric e-motion 260 combi M injection moulding machine equipped with two injection units and a central rotary platen. Using a stack mould from Hack, 24-well cell culture plates and matching polycarbonate lids are produced simultaneously in a single shot – with a cycle time of just 11 seconds. The additional injection unit is arranged at an angle to shorten the hot runner path, enable central injection without weld lines and improve material protection. This manufacturing solution, featuring a side-entry robot from Ilsemann, delivers the entire process including assembly and packaging in a compact, ergonomic setup.
A key highlight is the validation solution jointly developed by ENGEL and toolmaker Hack. This system enables structured and digital documentation of all validation phases – from Design Qualification (DQ) to Performance Qualification (PQ). Machine- and tool-integrated sensor technology, combined with products from the ENGEL iQ family and standardised documentation modules, significantly reduce the effort required. As a result, the time- and personnel-intensive validation process is substantially shortened.
Technical Moulding: Saving resources and using installation space efficiently
Precision LSR seals for fuel cells are produced on the vertical ENGEL insert 150 – fully automated overmoulding with maximum accuracy in a minimal footprint. Image source: ENGEL
World premiere – New generation of electric tie-bar-less machines / Automated overmoulding of fittings
One of the highlights at the ENGEL stand is the world premiere of the latest generation of its electric tie-bar-less victory injection moulding machines. This new model is fast, clean, and energy-efficient, and also features a completely new technical design – delivering additional advantages for users.
On the new victory electric, fittings are produced with a cycle time of just 23 seconds. The mould includes large-volume core pulls, which are optimally supported by the free access provided by the tie-bar-less design. Thanks to ENGEL tie-bar-less technology, even large moulds can be used on comparatively small machines, saving space, energy and investment.
After injection moulding, the fittings are automatically equipped with seals. The production cell is equipped with two easix articulated robots to handle this step.
Blocks made from recycled material with high structural stability
On an all-electric e-mac 220 injection moulding machine with 2,200 kN clamping force, ENGEL is producing thick-walled, foamed construction blocks for the building industry. The material comes from yellow bag household waste, reprocessed by EREMA. Mould and foaming agent formulation are supplied by Moxietec. For optimum foam homogeneity, an optimised mixing screw is used during plasticising. The result: components with up to 30 % weight reduction and 10 % higher strength. This technology is particularly well suited for logistics pallets and as a substitute for concrete in construction applications.
As 100 % post-consumer recyclate with corresponding material fluctuations is processed, the new iQ weight control plus plays a key role. After defining just two parameters, the digital assistance system automatically adjusts the switchover point and pressure curve during every injection cycle. This reduces scrap by up to 50 %.
An integrated automation solution with servo sprue picker and an integrated conveyor belt inside the machine makes the cell particularly energy-efficient and compact.
Packaging: Scalable sustainability in series production Thin-walled cups with 30 % rPET produced using a stack mould
ENGEL is demonstrating a series-ready solution for processing rPET in thin-walled packaging on an all-electric e-motion 420 injection moulding machine with 4,200 kN clamping force. What was previously only feasible using hydraulic injection, ENGEL now achieves electrically. A 6+6-cavity stack mould from Plastisud is used to produce yoghurt cups made from 70 % virgin material and 30% bottle-grade rPET. The rPET is supplied by NGR and upgraded for food contact via Liquid-State Polycondensation.
This production setup delivers excellent repeatability at high performance. The combination of injection compression moulding, iQ motion control, and iQ weight control plus enables the manufacture of thin-walled, precise cups with minimal material usage. The application already complies with the requirements of the Packaging and Packaging Waste Directive for 2030. Moreover, it illustrates the potential to replace thermoforming as the preferred manufacturing process, enabling producers to save on upstream steps (film production) and material (trimming waste). ENGEL thus presents a practical example of how sustainability and precision can be combined in an economically viable production environment.
On the all-electric ENGEL e-motion 420, thin-walled cups with 30 % rPET are manufactured in series production using a stack mould – compliant with the Packaging and Packaging Waste Directive 2030. Image source: ENGEL
inject AI: Digital intelligence for real-world production benefits
Smart assistance systems with practical impact
With inject AI, ENGEL is taking its inject 4.0 programme to the next level. At K 2025, ENGEL will showcase the next step toward self-optimising machines by integrating artificial intelligence into many new and existing ENGEL products.
The iQ process observer monitors up to 1,000 parameters per shot, detects process deviations in real time, and provides AI-supported automatic correction suggestions – a key contribution to process optimisation and scrap reduction. The systems continuously learn from the data of all connected machines, creating added value for every new project – a genuine boost for quality and efficiency.
e-connect portal with AI: Digital support for every shift
In the event of machine or process faults, a new AI-supported feature in the e-connect portal provides machine-specific assistance – quickly, precisely, around the clock, and in all languages. Thanks to intelligent search functionality in the ENGEL machine manuals, downtime can be significantly reduced. The system will be available as a pilot series in time for K 2025.
Humans and AI – a team effort
ENGEL does not see AI as a replacement, but as a complement to human expertise. Adaptive assistance systems ease the burden on personnel, stabilise processes and increase equipment availability – an especially valuable benefit in times of skilled labour shortages. In this way, the self-regulating machine is gradually becoming a reality.
ENGEL – Your Partner for the Future
At K 2025, ENGEL is demonstrating how machines, automation, and digital systems can be combined into fully integrated manufacturing solutions. Each exhibit on the stand represents a production cell precisely tailored to meet specific customer requirements – and a well-considered, economically viable response to those needs. The exhibits are complemented by expert corners on topics such as plastification, technologies, temperature control, and training, where ENGEL presents customer-focused solutions.
Whether lightweight construction, the use of recyclates, validation, or process stability: ENGEL thinks in terms of solutions. The trade fair appearance encourages open, hands-on and forward- looking dialogue. Because while plastics processing may not be getting any easier, with ENGEL it remains manageable, flexible, and efficient.
Efficient Plastics Solutions for a Sustainable and Digital Age
Future-oriented plastics firms must boost production, quality, and efficiency while operating responsibly, supporting the circular economy, and providing desirable employment opportunities. How are they able to achieve that? The collaboration between Hexpol TPE and the process technology provider, MAAG, is an example of how engaging with other specialists is the most effective method.
From the yellow bag into a dash- board: thanks to high-quality plastics recycling, this circular economy is no longer a pipe dream. But creating compounds with proper- ties that meet the high expectations of companies in the automotive sec- tor and other demanding industries calls for high level of process engineering expertise. Anybody looking for this expertise will find it at Hex-pol TPE in Lichtenfels. The company manufactures thermoplastic elastomers, soft PVCs, TPE compounds with TPS, TPO, TPV, and TPU, additives and masterbatches. Across the entire portfolio, great importance is attached to high-performance compounds with top quality and, increasingly, with a growing proportion of PIR and PCR plastics. Particularly challenging in this context is the processing of contaminated and heterogeneous postconsumer recycled materials (PCR) – i.e. the materials collected by the dual systems.
Top Mounted PEARLO Underwater Pelletizer for clear and clean floor space
The challenge of higher quality
Hexpol TPE is on the right route, as evidenced by the growing demand. The business has acquired a number of new machineries in recent years to meet the rising standards for quality. The firm has depended more and more on MAAG’s Pearlo machine series for pelletizing systems. With throughputs of up to 42,000 kilos per hour, the underwater pelletizing system promises profitable production of a variety of polymers and thermoplastics. In 2017, Hexpol TPE made the decision to purchase its first pelletizing system from the Pearlo series. A number of additional pelletizing systems were added to the machine park in the next years.
The latest investment, a Pearlo 160, was added in 2023 and is impressing in production just as expected: The machine is suspended above the production line. In this top-mounted configuration, the floor under all the components remains free and accessible because the machine is suspended from an overhead rail system. Quick-disconnect-adapters involve just one bolt, whereas previously twelve had to be loosened and then fitted again. “This offers immense time savings during assembly and cleaning of the system that can now be done much faster,” reports Dominik Fehn, Process Engineering Manager at Hexpol TPE in Lichtenfels. Much less effort is required when a machine weighing 400 kilograms is suspended from the ceiling and can be moved with one hand rather than being pushed on wheels.
As Hexpol TPE attaches great importance to reducing the workload on its employees, this system is a perfect addition to make life even easier for the workforce. MAAG offers two-axis machines that can be moved in two directions. This means production staff can clean and set up faster, and components do not have to be readjusted. “This is a huge and important reduction in workload, allows quick and stress-free retooling and saves unnecessary energy,” emphasizes Fehn.
The new Pearlo has been proving its worth in Lichtenfels ever since. “We decided to take this step in order to increase production efficiency while reducing the workload,” explains Fehn.
Hexpol TPE Plant in Lichtenfels, Germany
Automation for greater efficiency
All the same, high quality alone is not enough to stay competitive on the international stage – the efficiency also has to be right. In order to enable Hexpol TPE to increase quality, efficiency, and sustainability in equal measure, the company launched its “Zero Waste” project in 2024. The goal: To significantly reduce waste from production, increase the efficiency of all processes, and automate the processes wherever possible.
Dominik Fehn also discussed this with well-established partners of the company – and found MAAG to have comprehensive consulting expertise: “I was really surprised by the wide range of workshops and training courses that MAAG offers on these topics,” says Fehn.
Workshop highlights potential
In a multi-day workshop on site in Lichtenfels tailored to the defined goals, MAAG provided support in identifying optimization potentials in all areas of production: machines and production planning, personnel and teamwork, as well as training courses. The targeted workshop was split into different process steps, in which employees from the individual groups at the site were interviewed and involved in group work. First, open questions were used to identify the general potentials specific to the company; the results were then grouped and prioritized, and areas for optimization were identified. Once the ice had been broken, any potential for improving the machines was identified and the resulting measures were prioritized.
PEARLO 160 production line
Cause-and-effects analysis
The subsequent cause-and-effects analysis characterized the results and put them into a structure. The work results obtained here were grouped, summarized according to lean principles, and the resulting tasks were prioritized. Finally, all arguments for solutions were identified and classified according to the following criteria: feasibility and impact, difficulty of implementation, implementation costs, and determination of the implementation priorities. After identifying the “take a closer look” arguments, including a definition of the options to be considered, the “don’ts” were of course also derived.
The results of the workshop: Factors directly related to the machine – such as the selection of die plates and knife heads, the use of optimized/ predefined process settings, or the planning of maintenance intervals – can contribute to optimization. Much greater potential was identified, however, in factors such as the better utilization of talent within the company, more teamwork, the avoidance of waiting times and excessive processing, or simply reducing over-production. The path to achieving this lies in greater data availability and transparency in order to enable the necessary steps to be identified. Whether through automation or process optimization, Hexpol TPE expects digitalization to result in higher efficiency and better working conditions in all areas. “We will be investing in this further development over the next few years,” says Dominik Fehn.
Modernized Technology Center Welcomes Industry Back in Rednitzhembach
Since the autumn of 2022, the Arburg Technology Center (ATC) near Rednitzhembach has undergone considerable renovations, modernizations, and expansions. The Arburg team provided devoted and adaptable on-site customer assistance throughout the transition period. In front of ATC Manager Johannes Herbst and project participants, Tobias Baur, Managing Director Sales and After Sales, and Michael Hehl, Managing Partner of Arburg and Spokesman of the Management Board, cut the ribbon for the official reopening on July 3, 2025. After the festivities, there was an Open Day with about 170 attendees.
Reopening of the ATC Rednitzhembach (from right): Arburg Managing Director Tobias Baur, Arburg Managing Partner Michael Hehl, ATC Manager Johannes Herbst, Florian Schmitz, Arburg Director Building Services Engineering, Arburg architect Dieter Novotny and Bernd Schmid, Arburg Director External Sales Germany. Photos Credi: ARBURG
“The ATC Rednitzhembach has played an important role for our customers for 30 years and underlines the great importance of this German site for Arburg,” emphasised Michael Hehl in his opening speech, welcoming the guests and the Arburg team on behalf of the shareholders and the entire Arburg organisation. “We are very proud of what has been created here in the three years of the conversion phase: a building for the future that combines aesthetics with functionality and environmental protection in an outstanding way”.
Comprehensive extension and role model for energy efficiency
“Regardless of whether Arburg is developing or building products and processes – high-tech and innovation are always combined with resource conservation and sustainability,” says Michael Hehl. The extensive renovation and expansion work includes an extension of the showroom and doubling the total floor space to 1,600 square metres.
In terms of energy efficiency, the new building is around 25 per cent better than required by the Energy Saving Ordinance. The photovoltaic system alone generates 65,000 kWh per year, which is equivalent to the annual consumption of around 20 four-person households. A battery storage system ensures that 100 per cent of the electricity generated can be used in the ATC. A geothermal system with a heat pump was installed to heat the building in winter and to cool it in summer. This system has 24 probes, each 64 metres long. In addition, there are surface heating systems such as heating/cooling ceilings and concrete core temperature control. Furthermore, the waste heat generated by machines and in the IT room is utilised directly in heating mode and in cooling mode by storing it in the geothermal system. Thanks to the innovative technology for heating and cooling, buildings and machines can be supplied with CO2-neutral energy.
Reopening of the ATC Rednitzhembach: The extensive renovation and modernisation work included the installation of photovoltaic and geothermal systems and a triple-insulated glass façade. Photos Credi: ARBURG
Three-year transition period
The Rednitzhembach Sales and Service Center in Middle Franconia has been a popular point of contact for customers and interested parties from southern and eastern Germany since 1995. Today, ten employees work at the ATC, supported by twelve service technicians.
During the three-year construction period, the team in Rednitzhembach continued to provide comprehensive support for its customers. Administrative work was carried out in a rented office building nearby. Technical application training courses were held on the customers’ premises and were very well received. Two Allrounders were installed on a toolmaking partner’s premises for sampling, trials and technical application presentations.
Open House: Around 170 customers and partners took the opportunity to see the modernised ATC Rednitzhembach for themselves. Exciting applications could be seen “live” on Allrounders. Photos Credi: ARBURG
“Open Day” in modern premises
The expanded showroom now offers space for nine Allrounder injection moulding machines with clamping forces ranging from 350 to 3,200 kN. These are used for sampling and training purposes and include one vertical machine and two multi-component Allrounders. The entire robotic portfolio is also covered, including integral pickers, linear Multilift robotic systems and six-axis robots.
At the “Open Day”, guests were able to see the new premises for themselves. Innovative applications could be viewed “live” on all nine Allrounders – from the electric Allrounder 270 A, which produced cutlery from a compound of bioplastics and sunflower seed shells, to the two-component Allrounder More 2000 for the fully automated production of Frisbee discs in a hard-soft compound. There were also exciting specialist presentations on hot topics such as digitalisation, smart assistants and turnkey.
Enhanced Pump Design Responds to Demands of Sustainable Processing
The importance of so-called post-consumer trash as a raw material supply is growing. Since it frequently gets combined with tougher contaminants like sand, glass splinters, and metal foil residues, it normally needs to be sorted first. Either contact surfaces or extremely narrow spaces are used to seal throughout the pump pressure building process. At those locations, the foreign particles cause significant wear or seizing-up, which can reduce durability and result in unscheduled stoppages. New solutions increase the range of applications, increase robustness, and prolong service life. Additionally, the solutions work well with heavily loaded polymers.
The circular economy is subject to enormous cost pressure, while the basic raw materials are currently often cheaper. Beyond that the processing of post-consumer waste is relatively costly. This is primarily because it is difficult to filter out the impurities to a sufficiently clean quality. Consequently, the final purity of the recyclate has a massive influence on the achievable price.
Extrusion system: Users can extend service life with timing gears. Photo Credit: Maag Pump Systems
High-quality recycling of recovered raw materials
There are basically two different recycling concepts that make up a circular economy. The first is pure filtration, or mechanical recycling of the polymer mix, whereby the foreign particles are removed from the existing polymer melt. The achievable purity is however limited in this process. It is therefore often unsuitable for direct contact with foodstuffs, and for applications imposing higher demands.
The second concept, chemical recycling, depolymerizes the polymer chains in the recycling process. This process either produces a low-viscosity intermediate product or breaks the raw material down directly into partially gaseous streams. Polymer generated from these recovered raw materials is of high quality, and can be used without restriction. The process sequence is more complex than mechanical recycling, however.
Extending service life, avoiding sudden stoppages
Both process concepts are the same initially. The post-consumer waste must first be shredded, and manually precleaned to remove coarse impurities. The more tolerant the downstream process chain, the leaner the precleaning can be implemented. Significant wear along the entire process chain is a familiar aspect of post-consumer waste recycling, and it is completely normal for many components to need replacement every year or two. The end of life of wearing parts is usually signaled by changing process parameters such as rotation speeds or temperatures. So their replacement can be planned and coordinated with other maintenance work. Alongside the general requirement to extend service life, it is extremely important to avoid sudden stoppages and unplanned maintenance interventions.
Filler agglomerates block flow channels
In highly filled mixes there are hardly any gaps between the fillers, and the interaction of the solids severely impedes the flow. Solids are repeatedly ground up in the flow, and the mix has limited flowability. Filler agglomerates behave similarly to impurities in recyclate, and can cause blockages. This is because the filler agglomerates tend to block flow channels – especially converging channels.
Higher concentrations can settle in converging flow channels, and the pressure pushes the polymer further out of the gaps between the filler particles, which further compacts the fillers, practically solidifying them. The pump is in effect blocked, usually without causing major damage. After cleaning – entailing a major disruption of the process – the pump can be run normally again.
More robust design
The latest-generation of pumps from Maag feature a design that no longer collects dirt in an annular channel between the bearing and shafts. This means the new design is inherently less susceptible to damage from solid impurities, oversized fillers or high filler concentrations. This attribute has proved its worth right from launch.
Traditional gear pumps that have not yet been optimized for such applications have some problem areas that are at high risk if the pumped material is contaminated. The worst impact is from medium-sized ductile metal parts about 0.2 mm in size or larger (depending on pump size) being drawn into the slide bearing. This then leads to seizing-up of the shaft in the bearing: crushing, and ultimately melting, of the particle, which consequently melts and tears open the bearing and the shafts. In the worst case, cold welding occurs; the pump comes to an abrupt stop, and can no longer be used. In the best case, the surface is broken up, merely impairing the operating limits to some extent. This does, however, mean that even minor faults can stop the pump running.
With the system for recycling post-consumer waste, users contribute to the circular economy. Photo Credit: Maag Pump Systems
Fewer teeth mean that the product is less compacted in the final meshing phase.
Gear pumps are generally optimized in terms of their bearings to work very reliably with a wide range of clean polymers. Because pure polymers in some instances have very extreme properties, good filling of the bearings is the main challenge in order to maintain a stable lubricating film. Recycling plants are always fed with a mixture, so the most extreme polymer properties such as melt breakage are not encountered. In particular, the mix contains various processing aids that have been added to counteract such phenomena. This opens up entirely new possibilities for the design of bearings. Instead of allowing open access to the bearing, the manufacturer has incorporated a local filtration at the bearing lubrication inlet. A special geometry ensures that the bearing is still supplied with melt, but the larger particles are no longer drawn into the bearing gap. Whatever still gets in can cause only limited, minor wear. This does result in the bearing geometry being washed out over time, though without causing serious unforeseeable damage.
The service life of the interior components is normally limited by general wear, and end of life is signaled by a gradual decrease in efficiency. This means that the replacement of wearing parts can be planned and carried out together with other maintenance work. As opposed to traditional filtration systems with filter surfaces, the gap does not clog up, and the teeth carry the particles into an area of the bearing where, almost like a backwash filter, the dirt is pushed back out of the gap.
Service life extended
In an application in which the pump had a service life of around two to three weeks, the manufacturer was able to increase it to between 18 and 24 months by incorporating the filtering bearings. Above all, abrupt severe failure due to bearing seizure is now completely eliminated. This represents a massive improvement in terms of reliability and robustness, makes production plannable, and is essential to a cost-effective operation.
When processing highly filled polymers, filtration reduces the concentration of fillers in the bearing. The reduction in filler significantly improves the convergent bearing flow. This bearing design enables a higher filler concentration in the conveyed polymer melt than would otherwise be possible.
Greatly reduce pre-cleaning
If users are forced to generate very high pres – sures at very high temperatures, the filtering bearings are no longer sufficient for stable operation with the impurities in the post-con – sumer waste. In such applications, a solution involving external lubrication of the bearings is deployed. A small amount of clean polymer (about 0.5 – 1 percent) that is compatible with the process and of sufficient viscosity is injected into the bearings. This ensures that the shaft is supported securely. Mixing the lubricant into the process slightly increases the downstream flow rate. At first glance, such an approach appears costly. But this process can, in some cases, substantially reduce the required pre – cleaning, and so is economical for that reason alone.
The special toothing to the right traps less polymer and leaves wider flow paths open. Photo Credit: Maag Pump Systems
Gear toothing made more robust
Another area in gear pumps that causes significant wear or blockages is the tooth meshing. When the second flank meshes, the remaining product stream must flow out via longer routes and through a narrower gap. Larger pieces of contaminant, in particular, can stick to the tooth root at this point, while the opposing tooth con – tinues to engage further into the tooth space. These larger pieces are then pressed together into the remaining gap between the tooth head and root. The more the trapped volume has to be reduced, the greater the risk of blockage. To prevent this effect, the manufacturer uses a special toothing design with fewer teeth for recycling applications. Fewer teeth not only mean that the product is less compacted in the final meshing phase; there is also much more room for the product to flow out in the first meshing phase while the opposing tooth is engaging in the tooth space. This additionally reduces the loading on the gears due to lower squeezing pressures.
Wear usually occurs on the contacting tooth flanks where the driving shaft drives the rotat – ing shaft. However, although the flank pressure increases due to the increased curvature of the optimized geometry, this new process means that far fewer particles are effectively trapped and ground between the flanks, and so the ser – vice life is extended.
Tooth flank wear significantly reduced
If the recyclate is so contaminated that the wear between the tooth flanks is unacceptable, users can install a timing gear between the reduction gear and the pump. This intermediate gear then drives both shafts simultaneously so that no torque transmission takes place in the pump, and the tooth flanks run practically contact-free. This significantly reduces tooth flank wear. The introduction of filtering bearings has extended service life from 2 or 3 months to between 18 and 24 months.
Changing to an optimized gear geometry also has the advantage that the teeth are thicker and more robust. This means that even larger particles can only cause dents and deformations in the teeth; they will not usually break.
Flexible modular system improves circular economy
Pumps that prevent accumulation of dirt in the annular channel between the shaft and bearing are suitable as a basic system. Moreover, the filtering bearings in conjunction with the optimized gear toothing on the shafts cope well with medium degrees of contamination and medium filler concentrations, provided the required pressure is not too high.
If contamination is higher, users can counteract the primary wear in the tooth meshing by installing a timing gear. This makes sense where users want to maximize service life, or where replacement part costs exceed the investment in the timing gear.
There is also an option to lubricate the bearings externally. A small additional extruder is integrated into the system to continuously feeds the clean polymer melt to the pump in order to lubricate the bearing. This is the only way to enable applications with higher pressures and thinner viscosities that would otherwise simply be inconceivable. With these measures, users can make much more out of post-consumer waste, and so contribute to the circular economy. Even heavily contaminated waste collected from nature can increasingly be included, which increases the incentive for collection for recycling.
However, infrastructure alone isn’t enough. To capitalize on these improvements, local manufacturers need advanced machinery and technical know-how. This is where 
