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STADLER’s Mission to Maximize Paper Recycling Efficiency

STADLER’s Mission to Maximize Paper Recycling Efficiency

There has never been a greater need for environmentally friendly packaging options, especially in the food sector where customers are gravitating toward goods that make environmental commitments. Due to both commercial forces and regulatory requirements, this tendency has caused a notable shift towards packaging made of paper. The market for paper packaging is estimated to increase at compound annual growth rates (CAGRs) of 4.8% and 3.9%, respectively, by 2030, reaching USD 97.6 billion in Europe and USD 75.64 billion in North America in 2025. Due to customer preferences and sustainability objectives, the food industry is leading this change, with liquid cartons emerging as one of the package options with the quickest rate of growth.

Even though paper solutions are being adopted quickly, a significant volume of paper is still not recycled, particularly from mixed waste streams. According to studies, Germany’s lightweight packaging trash alone has the potential to produce over 100,000 tons of high-quality paper a year. However, this resource is mostly unrealized because of a number of enduring issues. The technical viability of recycling paper from mixed trash has advanced significantly thanks to the EnEWA project, a joint venture between STADLER Anlagenbau GmbH, academic institutions, and other industry experts. However, there are regulatory barriers that need to be removed in order to fully realize this potential.

The Rising Challenge of Paper-based Packaging

Paper packaging is becoming increasingly popular in the food business due to consumer demand and environmental concerns. Businesses are making significant investments in environmentally friendly paper solutions, and innovations like Pulpex’s paper bottles created from wood pulp that is supplied sustainably demonstrate the industry’s dedication to minimizing its environmental impact. Even with these developments, recycling paper is still a challenging problem, especially when it comes to composite packaging.

Multiple layers of materials, such as paper, plastic, and aluminum, are combined to create composite packaging, which is frequently used in food goods. Because these layers are challenging to separate, recycling is a labor-intensive and potentially contaminated procedure. Additionally, consumers may find some of the new composite packages puzzling since they may look like they are made entirely of paper, but they actually comprise layers of other materials. Even while technology developments have showed promise, there are still many obstacles because of the regulatory framework.

The Regulatory Hurdle

The regulatory landscape is designed to ensure the safety and quality of recycled materials used in food contact applications, though approaches vary. EU regulations are prescriptive, requiring detailed testing, documentation, and often pre-market authorisation, reflecting a precautionary approach to ensure consumer safety. Germany’s BfR Recommendation XXXVI, although officially a guideline, imposes strict criteria to minimise contamination risks, effectively restricting the use of recycling paper from mixed streams for food applications, influencing industry practices and contractual agreements.

Regulations in other EU countries, such as Italy and Spain, are less prescriptive but still demand a high level of scrutiny on the sources of recycled fibres, posing challenges for using mixed waste paper in food packaging, reflecting a broader European commitment to maintaining safety in recycled materials. Scandinavian nations comply with EU regulations while adding national guidelines to address specific regional concerns, ensuring high consumer safety. North American regulations, on the other hand, focus more on general safety and good manufacturing practices, allowing more flexibility but placing greater responsibility on manufacturers to ensure compliance.

“The EnEWA project has shown that with the right technological adjustments, such as improved sorting and sanitisation processes, high-quality paper can be recycled from mixed waste streams,” explains Annika Ludes, Product Engineer at STADLER. “However, to fully realize this potential, changes in the regulatory landscape are essential. Amendments to guidelines like the BfR Recommendation XXXVI could pave the way for more sustainable use of recycled paper in the food industry.”

The EnEWA Project’s Contributions

The EnEWA project has provided compelling evidence that recycling paper from mixed waste is technically feasible. The project demonstrated that through innovative sorting technologies and adapted processes with dry-mechanical sorting, wet processing, and sanitization, secondary fibres could be obtained and used in paper production without significant contamination issues. Special sorting technologies, like Near-Infrared (NIR) sensors, were optimised to identify and separate composites. Additionally, processes like hot dispersion under overpressure proved successful in reducing microbiological contamination.

Beyond technological advancements, the EnEWA project has engaged with regulatory authorities, advocating for updates to waste management guidelines and amendments to restrictive regulations. It has developed recommendations towards a more flexible regulatory approach, especially for applications outside the food sector or for dry food packaging, backed by scientific data from worst-case scenario experiments. The project has also held workshops involving representatives from stakeholders including the packaging industry, sorting facility operators and paper recyclers.

The Future of Paper Recycling

While the EnEWA project has concluded, its legacy continues. STADLER, now an associated partner in the SPaRe project, is working to further enhance the energy efficiency of the paper recycling cycle. This initiative aims to optimise the utilisation of residual materials in paper production, potentially saving 1 TWh of energy annually – equivalent to 1.6% of the annual energy consumption of the paper industry – and reducing greenhouse gas emissions by approximately 350,000 tons of CO2 equivalents per year.

By demonstrating that there is technology to recycle large quantities of paper from mixed waste, the EnEWA project has brought attention to the unrealized potential of paper recycling. To fully realize this potential, though, a determined effort is needed to remove legal restrictions and enhance waste management procedures. By tackling these issues, we can transform what is presently a wasted resource into a vital component of sustainable packaging, propelling the sector toward a more ecologically friendly and circular future.

http://www.w-stadler.de

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Crafting Ultra-Thin, Eco-Friendly Hygiene Packaging Films with Superior Performance

Crafting Ultra-Thin, Eco-Friendly Hygiene Packaging Films with Superior Performance

Challenge

To create a hygiene compression package incorporating recycled content without compromising the film processability or the overall performance of the package In response to consumer preferences and brand owner commitments, many converters are facing the challenge of developing hygiene compression packaging films with sustainability benefits such as downgauging, incorporation of recycled content, and design for recyclability. Examples of these benefits can be demonstrated with monomaterial polyethylene (PE) solutions that can be recycled and that require a reduced amount of virgin PE material because of a reduction in film thickness and/or the incorporation of recycled content. The challenge lies in achieving these goals while maintaining the film machinability and package performance.

The films were then converted on Hudson-Sharp’s Apollo wicket machine. The wicketer is ideally suited for monomaterial PE films, which may or may not incorporate recycled content, even at very thin gauges. Thanks to the excellent sealability and easy side cutting/punching provided by ExxonMobil’s two PE film formulations, high machine output can be achieved. Customers can continue to benefit from fast changeovers, while achieving high output speeds.

Solution

Design of two recyclable solutions with reduced film thickness and/or the incorporation of up to 35% recycled content A thorough collaboration throughout the full value chain has led to the development of two monomaterial PE film solutions, using Exceed Tough+ m 0518 metallocene polyethylene. In ExxonMobil’s formulation, the use of Exceed Tough+ m 0518 helps enhance the production of films with remarkable toughness and puncture resistance. When combined with ExxonMobil HD 6107FL polymers, it results in high stiffness and excellent creep resistance, ensuring that the package maintains its dimensional stability throughout and after the packaging process. Minor additions of ExxonMobil LD 07523 polymers can be employed to adjust processability and optical features. By leveraging just three PE grades, it is possible to reduce the film thickness and/or incorporate up to 35% recycled content while still meeting performance and processability requirements. The films were made on lines located in an ExxonMobil facility.

The package was subsequently formed and sealed using Optima’s machinery, which is specifically calibrated to handle these materials while ensuring optimal performance and quality. The two PE films produced by ExxonMobil demonstrated easy machinability on Optima’s equipment, exhibiting sufficient stiffness to prevent film elongation during handling and a good coefficient of friction for the grippers. These attributes are essential for maintaining the shape and functionality of the package, helping the products to be securely contained.

https://www.exxonmobilchemical.com/en

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Circular Valley Convention 2025: Driving Circular Business & Sustainability

Circular Valley Convention 2025: Driving Circular Business & Sustainability

In just a few days, the Circular Valley Convention (CVC) will open its doors at the Areal Böhler in Düsseldorf. On March 12-13, 2025, this pioneering plat-form for the industrial circular economy will bring together leading figures from business, science, politics, and society under the theme “Uniting In-dustries for a Circular Tomorrow”. With over 100 exhibitors, 200 top speak-ers, inspiring presentations, groundbreaking innovations, and premium net-working opportunities, CVC provides a unique platform to actively shape the transition towards a circular economy.

Conference program bridging science and practice

A central pillar of the Circular Valley Convention is its comprehensive con-ference program. Key topics include the development of efficient value chains, core technologies for circular transformation, and sustainable mate-rial management. Across three stages, renowned thought leaders and in-dustry experts will offer valuable insights into innovations, strategies, and global trends that are shaping the circular world of tomorrow. The Main Stage is structured into seven sessions covering circular plastics, packag-ing, construction, consumer goods, digitalization, logistics, and circular economy business models.

In addition to keynotes, panel discussions, and presentations on the Main Stage, attendees should not miss the Innovation Stage, where start-ups, researchers, and established companies will showcase cutting-edge strat-egies and technologies driving circular transformation. Hands-on master-classes will provide in-depth knowledge of specific circular applications.

For detailed information on the Main Stage program, please refer to pages 3-7 of this document.

An innovative event format that encourages sharing and networking

The Circular Valley Convention seamlessly integrates conference, expo, and networking in a groundbreaking format. On March 12-13, 2025, Düs-seldorf will become the global hub for the circular economy, offering a plat-form for international decision-makers across business, science, politics, and society.

Designated networking areas will facilitate cross-sector collaboration and partnerships. The “Circular Night” event on March 12, 2025, will provide an exclusive setting for relaxed networking over music, drinks, and dinner.

A circular marketplace with a holistic approach

The Circular Valley Convention connects science and industry, theory and practice. It covers all dimensions of the circular economy and the entire value chain across industries and materials.

In the expo area, more than 100 exhibitors – including Canon, SAP, Epson, Ernst & Young, Pöppelmann, Fraunhofer CCPE, Siegfried Jacob Metallwerke, PGS Group, Brüninghoff, the Leonhard Kurz Foundation, and many more – will showcase concrete circular economy solutions. The CVC will serve as a global marketplace for circular innovations, featuring world-leading corporations, mid-sized enterprises, and start-ups presenting groundbreaking developments, market-ready products, forward-thinking materials, and digital solutions. These solutions span all phases of the cir-cular economy, from the use of renewable raw materials to product design, manufacturing, logistics, product utilization, and end-of-life processes such as collection, sorting, and recycling.

“The Circular Valley Convention provides start-ups, mid-sized businesses, and global market leaders with a unique opportunity to position themselves as pioneers in the circular economy and engage with potential customers for their circular solutions”, emphasizes Philip Scheffler, Project Lead of the Circular Valley Convention at Messe Düsseldorf GmbH. “At the same time, CVC serves as a content hub for the circular economy, delivering key im-pulses for a sustainable and resource-efficient economic model. This makes it a valuable event for all participants.”

All speakers, all sessions: An overview of the Main Stage program

At the Main Stage of the Circular Valley Convention, renowned thought leaders and decision-makers from business, science, and politics will pre-sent their insights and visions for the future of the circular economy.

Opening remarks at the CVC

The CVC will open on Wednesday, March 12, with speeches from Wolfram N. Diener, Chairman of the Management Board of Messe Düsseldorf GmbH, the organizing body, along with key representatives from the event’s partner organizations: Dr. Carsten Gerhardt, Chairman of the Circular Valley Foundation, and Prof.  of Institute, Fraunhofer UMSICHT; also present will be Dr. Claas Oeh-lmann, CEO of the BDI-Initiative Cir Dr.-Ing. Manfred Renner, Headcular Economy. Moderator Chérine de Bruijn will guide the audience through the event.

Further keynote addresses will be delivered by Steffi Lemke, Federal Min-ister for the Environment, Nature Conservation, Nuclear Safety, and Consumer Protection BMUV; Hendrik Wüst, Minister President of North Rhine-Westphalia; and on the second day, Oliver Krischer, Minis-ter for the Environment, Nature Conservation, and Transport of North Rhine-Westphalia, and Dr. Stephan Keller, Lord Mayor of the City of Düsseldorf. These contributions underscore the importance of the Circular Valley Convention.

Keynotes: “Enabling Circular Economy”

The keynote speeches on the first day will highlight innovative approaches to advancing the circular economy. Prof. Dr.-Ing. Holger Hanselka, Presi-dent of the Fraunhofer Society, will discuss “The value creation potential of circularity: opportunities for innovation, efficiency and resource conserva-tion”. Dr. Carla Seidel, Vice President at BASF SE, will provide insights into BASF’s strategies and initiatives. Rebecca Tauer, Program Manager for Circular Economy at WWF Germany, will showcase how conserva-tion and business can collaborate to promote sustainable solutions. Ulrike Sapiro, CSO at Henkel, will present innovations for the circular economy transformation. Karin Huber-Heim, City of Vienna Endowed Professor-ship for Circular Economy & transformative business models, will dis-cuss the importance of partnerships in developing transformative business models. Joe Murphy, Executive Lead of the Business Network at the Ellen MacArthur Foundation, will share lessons from a decade of imple-menting circular economy principles. Dr. Martin Sonnenschein, Chairman of Heidelberger Druckmaschinen AG, will outline sustainable practices with-in his company.

On Thursday, the second day of the event, Prof. Lars M. Blank from RWTH Aachen University will discuss “Transforming the Chemical Indus-try into a Multidimensional Circular Economy”. Susanne Szech-Koundouros, Head of the sub-department: Raw Materials Policy, Cir-cular Economy, Resource Protection and Environmental Law at the Federal Ministry for Economic Affairs and Climate Action, will provide insights into “Perspective on Circular Economy in the Context of Federal Policy”.

Panel Discussions

On the first day, experts will debate the topic “From Green Deal to Indus-trial Deal: Economy as the basis for greater ecology and social stabil-ity”. Panelists include Ralf Düssel, Chairman of Plastics Europe e. V.; Prof. Dr. André Bardow, Department of Mechanical and Process Engi-neering at ETH Zurich; Prof. Dr. Henning Wilts, Head of Circular Economy Department at the Wuppertal Institute; and Ute Spring, EMEA R&D Director Packaging & Specialty Plastics at Dow Chemical.

Thursday’s panel will focus on “How to make plastic packaging circular? Opportunities and Challenges in Medium-Sized Businesses”. Partici-pants include Prof. Dr. Thomas Müller-Kirschbaum, Chief Scientist at the Circular Valley Foundation; Matthias Lesch, Managing Director of Pöppelmann Holding GmbH & Co. KG; Jens Stadter, CEO of Jokey SE; Andreas Vogt, Managing Director of Vogt Plastics; Georg Pescher, Managing Director DBNL, Alpla; and Gunda Rachut, Executive Board, Central Agency Packaging Register (ZSVR).

Thematic Sessions

Over both days, seven thematic sessions will explore circular business models, strategies, digital technologies, and the circular economy across various industries, including plastics, construction, electronics, packaging & printing, and logistics.

Session: “Value Chains for Plastics”

Auguste Laurent, CEO of Der Grüne Punkt Holding GmbH & Co. KG, will discuss key factors for the success of a fully circular value chain for plastics. Nicola Lelli, Senior Advisor at the Alliance to End Plastic Waste, will describe collaboration with stakeholders across the entire value chain to develop practical, globally scalable solutions. Prof. Dr.-Ing. Manfred Ren-ner, Head of Institute at Fraunhofer UMSICHT, will provide a compre-hensive overview of the circular economy with a focus on plastics. Addi-tionally, Dr. Daniel Schwaab, SVP Strategy at TOMRA, will address solu-tions for closing the plastics recycling loop, and Dr. Andreas Leitner, Sen-ior Vice President of Innovation & Technology at OMV AG, will present a case study on industrializing the circular economy.

Session: “Circular Construction Industry”

Prof. Dr. Philip Leistner, Institute Director of the Fraunhofer Institute for Building Physics IBP, will present solutions for addressing disruptions in the value chain. Thomas Nyhsen, Member of the Executive Board at STRABAG AG, will outline STRABAG’s path toward a sustainable future. Christian Hülsewig, CEO of Schüttflix Group, will introduce approaches to circular construction. Other speakers in this session include Felicitas Erfurt-Gordon, CEO, Erfurt & Sohn KG discussing “Circular Economy in the wallpaper industry”, and Frederick Verhelst, Head of Materials – Business Innovation Center, Lhoist Europe, presenting “Sustainability and circularity – core for the future in the lime industry”.

Session: “Circular Packaging & Printing”

Dr. Timo Fleßner, Senior Vice President Manufacturing API & Medical Devices Lead at Bayer AG, will explain how Bayer promotes sustainable production and supports the transition to circular options. Ralph Hopfen-sitz, Executive Senior Vice President Global Technology/CTO at LEONHARD KURZ Stiftung & Co. KG, will introduce sustainable finishing solutions and a recycling program for PET carrier materials. Prof. Dr. An-drea Büttner, Managing Director of the Fraunhofer Institute for Pro-cess Engineering and Packaging IVV, will emphasize the necessity of a holistic approach to the circular economy. Other speakers in this session include Dr. Jan Sültemeyer, Global Sustainability Leader, Avient Corpo-ration on “How additives and colorants can enhance plastic recycling”, Herwig Kirchberger, Managing Director, DELSCI GmbH on “The myths and truths about fiber-based flexible barrier packaging solutions” and Simone Mosca, CEO of Mosca GmbH, discussing “First steps to enable circular loops for flexible transport packaging”.

Session: “Electronic Products in a Circular Economy”

Dr. Markus Seidel, Senior Expert and Head of Research Circular Economy at BMW Group, will explain how the BMW Group implements circular economy principles and addresses key innovation areas. Prof. Christian Eigen, Deputy CEO of Medion AG (Lenovo), will showcase how Lenovo integrates circular economy strategies into smart design, us-age, and recycling. Prof. Simon Lux, Managing Director, Battery Facto-ry Münster Fraunhofer Research Institution Battery Cell Production FFB, will explore the role of batteries in the circular economy.

Session: “Circular Digitalization and Artificial Intelligence”

Sean Jones, Head of Sustainability at Microsoft, will discuss Microsoft’s sustainability efforts and how AI is being leveraged to support the circular economy. Darren West, Global Head of Circular Economy Solutions at SAP, will examine the role of digital solutions and AI in transforming the cir-cular economy. Jochen Bechtold, CEO, and Dr. Dorothea Pohlmann, CTO of Sustainability at Capgemini Engineering, will present digital transformation strategies and AI applications in the circular economy. Dr. Benedikt Brenken, Director R-Cycle at R-Cycle/ProData GmbH, will introduce the R-Cycle Initiative. Prof. Dr. Boris Otto, Director at Fraun-hofer ISST, will explain how data ecosystems support the circular econo-my.

Session: “Circular Business Models Strategies”

Marcus Sagitz, Managing Director Marketing & Corporate Affairs PreZero International at PreZero, will outline strategies and measures for implementing a zero-waste framework. Liam Condon, CEO of Johnson Matthey plc, will explore how circular business models and digital innova-tions accelerate the energy transition. Henning Reuter, Managing Direc-tor at Siegfried Jacob Metallwerke, will analyze the challenges of metal recycling in the global market. Marc Hetzer, Director, Business Consult-ing, Circular Ecosystems, EY Consulting GmbH, will talk about identify-ing circular value pools. Claudia Wegener, CIO of Interzero Circular So-lutions Germany GmbH, will emphasize the key role of digitalization in transforming the circular economy. Dipl. Ing. Gürsel Zorlu, Chief Growth Officer at PGS Group, will present “Tailored Solutions for Pallet Pooling” an innovative system for efficient pallet management. Smail Alhilali, Chief of the Division of Circular Economy & Green Industry at the United Nations Industrial Development Organization (UNIDO), will discuss UNIDO’s circular solutions for greening industrial supply chains and SMEs in developing countries.

Session: “Circular Logistics”

Markus Bangen, CEO of Port of Duisburg, will highlight how the world’s largest inland port contributes to the transformation through optimized infra-structure. Katja Busch, CCO DHL and Head of CSI (DHL Customer So-lutions & Innovation) of DHL, will emphasize the critical role of logistics in transitioning from linear to circular value chains. Dietmar Focke, CEO of Lufthansa Industry Solutions, will demonstrate how smart technologies improve efficiency and conserve resources in logistics processes. Prof. Dr. Uwe Clausen, Institute Director of the Fraunhofer Institute for Ma-terial Flow and Logistics (IML), will examine the importance of efficient logistics structures and processes for a successful circular economy. Other speakers in this session include Pradeep Pinakatt, Managing and Labor Director at Flughafen Düsseldorf GmbH, presenting “Exemplary Sus-tainability – The Path to a Sustainable Future for the Airport”, and Dr. Al-brecht Haase, Spokesman of the Management Board of GEFA Bank GmbH, alongside Andre Rolfes, Head of Sustainability at GEFA Bank, who will discuss challenges in financing battery-electric vehicles for com-mercial transport.

https://cvc-duesseldorf.com/

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How Quality Ensures Safety and Reliability in Micro Molding

How Quality Ensures Safety and Reliability in Micro Molding

Micro molding is one of the most advanced and challenging disciplines within precision manufacturing. As industries such as medical, electronics, automotive, and optics demand increasingly smaller, more intricate components, the pressure on micro molders to deliver high-precision, high-quality parts has never been greater. Quality is not just a desirable attribute in micro molding, it is an absolute necessity. This article explores the fundamental need for an unwavering focus on quality in micro molding and highlights key perspectives from Accumold, a leader in micro molding innovation. The article aims to show manufacturers, engineers, and procurement professionals the importance of prioritizing quality when selecting a micro molding specialist.
The Challenge of Miniaturization
As micro molding technology advances, parts are becoming increasingly smaller, often with features that are difficult to see with the naked eye. According to Cara Bloom, Senior Quality Engineer at Accumold, “as parts get smaller, generally the tolerances get smaller as well.” This presents a unique challenge, as maintaining consistent quality at such minuscule scales requires extreme precision. The margin for error is practically non-existent.
Micro molded components are used in applications where failure is not an option. Whether it is a microfluidic medical device, a micro-optical lens, or a high-frequency RF component, even the slightest deviation from the intended design can compromise performance, functionality, or even safety. This means manufacturers must invest in sophisticated metrology and validation processes to ensure that every part meets exact specifications.
Quality as an Integral Part of the Process
At Accumold, quality is not an afterthought, it is embedded into every stage of production. The company’s vertically integrated approach ensures that validation, metrology, and quality control are seamlessly integrated from the initial design phase through to final production. A key aspect of maintaining quality in micro molding is having the right metrology tools. “We need to have equipment that can handle the precision and accuracy
needed by these challenging projects,” says Bloom.
They use Zygo’s NewView 8300 Optical Profiler, a sub-nanometer precision non-contact white light interferometry instrument, for demanding applications. Critical parameters like lens prescriptions and flatness values, some of which have tolerances as small as tenths of a micron, may be measured thanks to this technology. In addition to optical metrology, they use a variety of cutting-edge instruments, such as Zone3 software, which enables CAD model-based part evaluation, Optical Gaging Products‘ (OGP) multi-sensor equipment with rotational, touch trigger, and laser interferometry. To further improve accuracy and efficiency, Keyence devices with pattern recognition software enable the inspection of microparts with little fixturing.
Measurement: A Necessary but Often Overlooked Consideration
One of the biggest mistakes companies make when selecting a micro molder is assuming that if a manufacturer can mold a part, they can also measure it effectively. However, micro metrology presents its own unique challenges, if you cannot measure it, you cannot make it. This highlights the importance of integrating measurement development into the early stages of product development. Accurate and repeatable measurements are essential for process validation, ensuring that molded parts consistently meet design intent. At Accumold, measurement development and Gage Repeatability and Reproducibility (Gage R&R) studies are key components of the company’s quality assurance process. By working closely with customers on design for manufacturability (DFM) and design for micro molding (DfMM), they helps optimize part designs for both moldability and metrology.
Compared to conventional injection molding, micro molding requires much more work to achieve quality.
Part size and tolerances present a significant obstacle. Micromolded components include characteristics that need to be magnified 10 times or more to be seen, and they can be sized in microns.
Non-contact techniques like laser scanning, white light interferometry, or high-resolution vision systems are necessary for measuring such tiny components. Part fixturing presents another difficulty. Accurate fixturing is necessary to guarantee repeatable and reproducible measurements. They have in-house-designed fixtures made of custom steel or 3D-printed plastic that securely hold items while they are being measured, guaranteeing precision and consistency.
Another problem is surface roughness, particularly in fields where surface polish is crucial, including optics and medical equipment. Delicate microparts’ surfaces can be altered or damaged by conventional tactile measurement instruments, hence non-contact metrology is the recommended approach. As was previously mentioned, They can assess surface roughness using white light interferometry without sacrificing part integrity.
Additionally, there is an ongoing discussion regarding in-lab versus in-process metrology. While traditional metrology was often confined to lab environments, modern micro molders increasingly integrate in-process metrology for real-time quality control. Accumold strategically assesses metrology requirements based on part complexity, volume, and tolerance levels to determine whether in-process or lab-based measurement is most
appropriate.
Continuous Improvement and the Future of Micro Molding Quality Assurance
Ensuring consistent quality in micro molding is an ongoing effort. As new metrology technologies emerge, micro molders must continually evaluate and adopt new equipment and methodologies to stay ahead. “We continually evaluate new equipment that may help us improve our measurements, either in efficiency or accuracy, as new metrology equipment enters the market,”Bloom explains. This commitment to continuous improvement ensures that they remain at the forefront of micro molding quality assurance. Additionally, automation is playing an increasingly vital role in micro metrology. Automated vision inspection (AVI) systems, integrated into molding processes, allow for rapid, repeatable inspections without human intervention. This reduces variability and increases throughput, ensuring that quality control keeps pace with high-volume production
demands.
For companies looking to leverage micro molding, the emphasis must always be on quality. It is not enough to select a manufacturer based solely on cost or turnaround time — quality must be the defining factor. When evaluating a potential micro molding partner, it is crucial to assess their metrology capabilities, ensuring they have the necessary equipment and expertise to measure parts accurately. Process validation should also be a key consideration, with quality control integrated throughout the entire manufacturing process.
Collaborating with a micro molder that prioritizes design for manufacturability and metrology optimization ensures that the final components will be both functional and precise. Furthermore, a commitment to continuous improvement and investment in advanced quality control methods are indicators of a reliable and forward-thinking micro molding specialist.

www.accu-mold.com

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Micrometal Group’s Sustainable Approach to PCE Manufacturing

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Micrometal Group’s Sustainable Approach to PCE Manufacturing

In the contemporary landscape of swift technological advancements, manufacturers in various sectors are encountering increasing demands for smaller, more intricate, and highly accurate components. Conventional manufacturing methods frequently struggle to adapt to these changing requirements, leading to innovation bottlenecks. Photo-chemical etching (PCE) has surfaced as a game-changing answer, with micrometal Group leading the way — a pioneer in precision manufacturing, assisting companies in overcoming obstacles and expanding the boundaries of design potential.

micrometal Group is setting new standards in high-precision, burr-free, and stress-free manufacturing, enabling industries such as medical, aerospace, automotive, and electronics to develop next-generation products without the constraints of traditional fabrication methods. Jochen Kern, Head of Sales and Marketing at micrometal Group, explains, “Innovation in precision manufacturing isn’t just about making things smaller — it’s about making them better, stronger, and more reliable while maintaining efficiency and scalability. PCE allows us to achieve this, and we are continually refining our processes to meet the exacting demands of modern industries.”

At micrometal Group, the investment in state-of-the-art technology and process optimization has led to major advancements in PCE. The capability to manufacture ultra-fine features and complex shapes is essential for applications such as medical implants, microfluidics, and high-frequency electronics. PCE also provides scalability and cost efficiency, enabling producers to easily move from prototyping to large-scale production without expensive tooling modifications. Moreover, the process is extremely adaptable, accommodating a vast array of materials, including stainless steel, titanium, and copper alloys, making it suitable for various industries. Another significant benefit is its eco-friendly and sustainable nature, producing minimal waste in comparison to conventional manufacturing techniques and lowering overall energy consumption.

The flexibility and precision of PCE make it an indispensable technology in industries where tolerances are tight and performance is critical.

Kern continues, “In the medical and healthcare sector, PCE is used to manufacture burr-free, high- precision surgical instruments, implantable components, and microfluidic devices that meet stringent regulatory compliance standards. For aerospace and defence, the technology allows for the creation of lightweight yet intricate components, such as fuel system parts, sensor elements, and shielding solutions, ensuring durability and enhanced performance in extreme environments. Meanwhile, in electronics and semiconductor applications, PCE is instrumental in producing high- precision EMI/RFI shielding, micro-connectors, and cooling solutions, supporting advancements in miniaturisation and ensuring signal integrity.”

As demand for greater precision, complexity, and efficiency continues to rise, micrometal Group remains committed to pushing the limits of what’s possible with PCE. “Our goal is to empower manufacturers with the tools they need to innovate without limits,” says Kern. “By continuously refining our expertise in PCE, we ensure that our partners stay ahead in an increasingly competitive market.”

For organizations aiming to improve accuracy, scalability, and effectiveness in their production methods, micrometal Group is a reliable ally. Get in touch with micrometal Group now to learn how our knowledge in photo-chemical etching can propel your next breakthrough.

www.micrometal.de

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KraussMaffei Reinforces Green Manufacturing at Extrusion Summit

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KraussMaffei Reinforces Green Manufacturing at Extrusion Summit

  • A unique industry get-together for extrusion and recycling
  • Keynote speeches and live demonstrations at the state-of-the-art Technology Center
  • Focus on Pipe & Profile and Recycling

KraussMaffei Extrusion welcomes industry experts to the Sustainable Extrusion Summit, a leading event for the plastics and recycling sectors, scheduled to occur in Laatzen near Hanover, Germany. Participants can anticipate a comprehensive agenda highlighting the newest advancements in extrusion and recycling technologies. The event is split into two primary themes: the emphasis on Pipe & Profile will take place on March 25 and 26, whereas March 26 and 27 will concentrate on recycling. Central to the event is the Technology Center, which sets new standards in extrusion through its distinctive development and application expertise.

The Technology Center is located within KraussMaffei Extrusion’s new building complex that spans 97,000 m². “With a total of 26 cutting-edge production lines, we are focused on technological excellence and sustainability, reinforcing our position as a leading entity in the plastics sector. We are excited to showcase this at the Sustainable Extrusion Summit and look forward to welcoming attendees from around the globe,” states Dr. Thomas Unger, Vice President of Technology at KraussMaffei Extrusion.

The event highlights include numerous live demonstrations, expert panels, and discussion forums, providing participants with opportunities to engage with industry leaders and explore current trends and innovations.

Pipe & Profile (March 25 – 26) – New multilayer pipe systems

The first two days will be dedicated to pipe and profile extrusion. Live demonstrations will showcase high-performance multilayer pipe production using the new pipe head, efficient solutions for PVC pipe manufacturing and pelletizing.

Top-class keynote speeches from partners such as Borealis, Kabelwerke Eupen, Baerlocher and Georg Fischer will provide insights into future trends and global challenges. Additionally, discussions will cover digital solutions and advanced control systems to enhance production efficiency and quality.

Recycling (March 26 – 27) – Experience the circular economy firsthand

The second half of the event will center on recycling and the circular economy. A key highlight will be the premiere of KraussMaffei Extrusion’s new machine concept for controlled upcycling of post-consumer plastic waste into high-quality automotive compounds. Another major feature is the energy-efficient and scalable production of food-safe rPET pellets.

Furthermore, the entire spectrum of recycling will be explored – from mechanical and solvent-based to chemical processes. Expert presentations from industry partners such as PureCycle Technology, Veolia, Lober, Polymetrix, and ExxonMobil, as well as from Plastics Europe and leading research institutions like IKV Aachen and IKK Hannover, will provide valuable insights into current developments and trends. The program will be complemented by groundbreaking technologies, including the use of artificial intelligence in compound development, smart sensor technology for in-line quality monitoring, and solutions for cable compounds in an electrified future.

www.kraussmaffei.com

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Strategic Acquisition Positions Husky Technologies for Future Growth

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Strategic Acquisition Positions Husky Technologies for Future Growth

Husky Technologies, renowned globally for its expertise in injection molding technology and solutions, is excited to declare its acquisition of secondary injection unit and rotary platen technologies from MGS Healthcare Manufacturing (MGS), a worldwide leader in healthcare manufacturing solutions. This acquisition enhances Husky’s status as a premier provider of integrated multi-material solutions across essential sectors, such as medical, packaging, and consumer electronics.

Advancing Innovation and Enhancing Customer Value

This acquisition facilitates the combination of precision secondary injection units and rotary platens with their state-of-the-art Altanium mold controller technology. By integrating these advanced multi-shot technologies, it enhances its capability to offer comprehensive, high-performance, turnkey solutions customized for the production of multi-material and multi-color applications.

The inclusion of these technologies allows them to broaden its range of fully integrated, multi-material solutions, boosting manufacturing efficiency and effectiveness. This also opens up new avenues for growth in the packaging, medical, personal, and homecare sectors, allowing producers to take advantage of a more complete array of innovative, high-performing solutions.

“This acquisition reinforces our commitment to innovation and excellence,” said Robert Domodossola, President of Systems and Tooling, Husky. “By bringing these complementary technologies into our portfolio, we are enhancing our ability to serve customers with integrated, high-performance solutions that drive efficiency and growth.”

“MGS is pleased to announce the divestiture of its Multishot product line to Husky. As a global leader in injection molding technology and a key strategic supplier to MGS, Husky is the ideal organization to take over and continue advancement of the Multishot product line,” said Shawn Krenke, Chief Technology Officer, MGS. “This divestiture allows MGS to concentrate on being a world-class contract development and manufacturing partner to our healthcare customers and we are dedicated to working closely with Husky to ensure a seamless transition and integration for all future and existing customers.”

Seamless Integration and Future Outlook

They are already working on ensuring a smooth integration of these technologies for customers and the new product additions will be showcased on Husky’s booth (Hall A, #627) at the upcoming Plastics Technology XPO, North America’s premier molding and moldmaking event, taking place in Illinois from March 18-20.

This acquisition marks a significant milestone in Husky’s continued expansion and commitment to providing innovative, end-to-end solutions for the global market.

https://www.husky.co/en/

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Compact, Efficient, and Reliable – PALFINGER P6

Compact, Efficient, and Reliable – PALFINGER P6

The new P6 radio remote control from PALFINGER will be available for TEC Loader Cranes from  2025. Together with the premium PALCOM P7 radio remote control, it completes the portfolio for the  TEC range. With its compact and lightweight design, the P6 helps crane operators to carry out their jobs efficiently and comfortably.

Industrial applications are becoming increasingly complex, and the demands on machines and their operation are constantly increasing. A compact control system for Loader Cranes is essential, especially for fast-paced applications in urban environments or for special jobs. Crane operators say it should be light and small. And yet as reliable and uncomplicated to operate as possible with maximum functionality. The P6 radio remote control, which was developed with partner SCANRECO and in close consultation with customers, is all this.

Precise control with a compact design

The P6 is one of the lightest and smallest radio remote controls with color display on the market and scores with its ease of use without sacrificing performance. Thanks to the redesigned linear lever and joysticks, the P6 offers even more precise control and allows crane operators to carry out even complex movements in a controlled and efficient manner. An integrated acceleration sensor also ensures the safety of crane operators: if the radio remote control registers a fall, for example, crane operation is stopped automatically. An ergonomic design, which is complemented by the carrying strap systems – either as a hip or shoulder strap – offers comfortable handling that makes everyday work much easier.

Starting in 2025, the P6 will be available, expanding the portfolio between the most comfortable high-end option, the PALCOM P7, and a lightweight, compact solution

Powerful battery

Thanks to the clear design and the integrated 3.5-inch TFT color display, users always have full control over the crane and its functions. With a battery life of more than 20 hours and the option of working for a further 20 hours with an additional battery, the P6 is also suitable for long periods of use. PALFINGER relies on a stable radio connection to ensure that work can be carried out undisturbed and without interruption under all circumstances. A 2.4 GHz frequency band, comparable to the familiar wireless LAN, ensures a reliable and powerful connection with the P6.

Flexible for different applications

With up to ten console variants, the P6 can be adapted to the individual functional scope of the TEC Loader Cranes. This allows companies to select the right control system for their needs and benefit from the rapid availability of spare parts and service. This makes the P6 a flexible solution in the most demanding application scenarios. “Direct customer feedback and cooperation with our partner SCANRECO have resulted in a radio remote control that is geared towards the real requirements of everyday working life and will make work assignments even safer, more efficient and more comfortable in the future,” explains Michael Völker, Head of Product Management Crane at PALFINGER EMEA GmbH. The P6 radio remote control can be ordered for all TEC Loader Cranes from PALFINGER from January 2025.

https://www.palfinger.com/

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The Next Leap in Innovation: How Businesses Can Stay Ahead

The Next Leap in Innovation: How Businesses Can Stay Ahead

By Erwin Busselot, Director Business Innovation & Solutions, Ricoh Graphic Communications, Ricoh Europe

Complex discussions regarding how digital printing can help printers enhance their offerings have taken the place of straightforward talks about the financial breakeven point between traditional and digital printing. This was an important conclusion in the Drupa Horizon Report.

Rolf Müller, the CEO of Printimo, which is part of the Optimo Service industrial services group, is well aware of this reality. This Swiss Print Service Provider (PSP) specializes in a variety of personalized products such as business cards, brochures, and books, and has invested in the latest RICOH Pro C9500 and RICOH Pro C7500 technology to handle a growing range of jobs. He notes, “Currently, we complete 60 percent of our jobs using digital printers, and this percentage continues to rise. In some cases, we produce just four pages of highly personalized content, while for other projects, we can create up to 100,000 flyers. Although offset printing is still a crucial part of our business for longer print runs, the adaptability and speed of digital printing are becoming increasingly essential. As the trend shifts from high-volume black-and-white printing to more customized outputs, we aimed to provide new alternatives with bolder colors to help our clients distinguish themselves in their markets.”

With its Pro C9500 and Pro C7500, Printimo is able to adapt to client needs, providing exceptional levels of personalization and innovation – swiftly, dependably, and effectively. Rolf Müller explains: “Our capacity for color printing has significantly increased. A 40-page brochure used to take 12 hours or 1.5 working days to print on our previous machines. Now, with the Pro C9500, we achieve the same output 30 percent faster and can dispatch it to the customer within a day. This represents a substantial time saving for our entire team – and enhances our customer service!”

“Stable and good print quality are at the top of our wish list,” states Rik Thijssen, Operations Manager, of Dutch scientific and educational book publisher Printforce. The specialist in on demand “single copy” books has installed two Pro C9500 devices to help it produce 15 to 20 thousand books every day, in three shifts, with an average print run of six copies.

The new systems are identical and interchangeable, ensuring sufficient capacity is always available. In addition to paper trays for three different paper types, they feature an XL tray for nonstandard paper sizes such as those required for dust jackets or covers with flaps. Process Engineer Rogier Calsijn explains: “The quality requirements for book covers are high. Especially when producing a single copy: any deviation on the cover can be grounds for the customer to complain or return. The quality of the covers is hardly an issue anymore, because the promised colour stability is actually delivered in practice.”

Europe’s first Pro C9500 at the Cantonal Printed Matter and Supplies Office (kdmz) of the Canton of Zurich in Switzerland, was chosen to support the production of a wide range of print output for the Canton of Zurich administration and other regional government departments and organisations. Rolf Thoma, Head of Procurement and Printing at kdmz, says: “In the first six months of a year especially, we print many time critical documents. These are highly sensitive print jobs, which we can’t give to external printers. Our old colour print solution could not deliver the speed and output quality we needed. We had to increase our inhouse capacity to facilitate seamless operations and ensure citizens received relevant documents on time.”

Markus Kirchhofer, Managing Director, adds: “Now we can produce complex graphics with more contrast, detail, and clarity. We can also streamline print jobs. For example, in the past, we sometimes printed the cover for a high-profile publication separately to the main content of a booklet or brochure. Now we can print everything on our Pro C9500 to simplify and accelerate the process. Thanks to the high reliability and efficiency of the Ricoh printers, we can increase our production volumes and deliver even the most complex print jobs faster. This improves our operational flexibility and enhances our service capabilities. With our new Ricoh production printers, we’re taking a big step forward in print quality.”

Poplar Services Printers was the inaugural company in Great Britain to install both a Pro C9500 and a Pro C7500, enabling them to enhance their capacity, introduce new print colors, and venture into short-run packaging. Managing Director Martin Winders states, “After previously operating the Ricoh Pro C9110, we believed it was a logical progression to upgrade to Ricoh’s latest technology. This advancement creates new opportunities, and having now completed comprehensive training and testing on all equipment, we are ready to showcase our new capabilities as the first company in the UK providing this complete service.” These and other print service providers have opted for the latest Ricoh Pro C9500 and Ricoh Pro C7500 technologies to boost their production abilities and broaden their service offerings. Discover how they can assist your business in exploring previously unreachable avenues for profitable growth.

https://www.ricoh.com/

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ENGEL’s Mexico Expansion: A Strategic Move for American Markets

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ENGEL’s Mexico Expansion: A Strategic Move for American Markets

ENGEL is strengthening its market presence in the Americas with the grand opening of a new production facility in Querétaro, Mexico. This strategic step marks a substantial expansion of ENGEL’s regional manufacturing capabilities, aimed at providing faster delivery times and increased availability of injection molding machines for customers across the Americas.

Stefan Engleder, CEO ENGEL Group

With this expansion, ENGEL is reinforcing its commitment to bringing production closer to customers in the region. The new facility allows increased efficiency and greater responsiveness to market demands.

Enhancing Regional Presence

The newly acquired facility provides ENGEL with the necessary capacity and infrastructure to significantly scale up production. “This expansion allows us to notably accelerate the start of production, ensuring increased availability of our machines for customers across the region,” says Stefan Engleder, CEO ENGEL Group.

Vanessa Malena, President ENGEL Americas, also reinforces the long-term commitment to the region: “Mexico plays a crucial role in our global production strategy and is a key market for injection molding technology. With this facility, we are enhancing our local manufacturing

footprint while ensuring a seamless experience for our customers, from production to after- sales support.”

Furthermore, the Querétaro facility offers ample space for future expansion. The decision to acquire this property was made with long-term growth in mind, ensuring that ENGEL can further increase production capacity if market demand continues to rise.

Vanessa Malena, President ENGEL Americas

Increasing production and growing the team

ENGEL will ramp up Mexican production rapidly, strengthening its ability to supply high-quality injection molding machines to customers across the Americas. The facility is designed to support a structured production flow, ensuring the flexibility needed to adapt to evolving market demands.

In addition to increasing production, ENGEL is also expanding its workforce. “We are growing our team significantly to support our manufacturing operations and customer servicein the region, says Nils Mayer, General Manager ENGEL Machinery Mexico.”This investment is not just about expanding our facility, but also about strengthening our expertiseand presence in the local market.”

A strategic investment for the future

The Querétaro facility will undergo a phased modernization to align with ENGEL’s high production standards. As part of a long-term investment plan, ENGEL is implementing key upgrades, including the further expansion of the flow-line manufacturing system, and extended machining capabilities. These improvements will optimize production efficiency while maintaining the company’s renowned quality standards.

Nils Mayer, General Manager ENGEL Machinery Mexico

ENGEL will manufacture the e-mac (all-electric small machine) and WINTEC t-win (hydraulic, two-platen large machine) series, as well as custom robots and automation solutions at this facility, ensuring a strong production base for these high-demand machines in the region. This investment in local manufacturing will allow ENGEL to better serve customers with tailored solutions and faster delivery times.

“With this expansion, we are well-positioned to meet the growing demand for injection molding machines in the region,” adds Stefan Engleder. “By reducing lead times and strengthening regional support, we are creating sustainable value for our customers. This facility is an important step in our continued expansion across the Americas.”

Long-Term Vision for ENGEL in Mexico

ENGEL views Mexico as a key industrial and production hub. The country offers a strong manufacturing base and skilled workforce, making it an ideal location for long-term investment. Additionally, Mexico and Latin America represent important and growing markets for injection molding technology.

Overall, the Americas continue to gain strategic importance for ENGEL, as they represent the largest addressable market for injection molding machines. With this investment, ENGEL strengthens its ability to meet customer needs efficiently while securing a leading position in the region.

www.engelglobal.com

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