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Roboterarme in einer modernen Elektronikfabrik als Symbol für Digitalisierung in der Kunststoffindustrie - K 2025

Embracing Digitalization

Digitalization is transforming the plastics and rubber industry and driving sustainable solutions.

For the plastics and rubber industry, the digital transformation not only means technological advancement, but also the opportunity to establish innovative business models and meet the increasing demands of the global market. Digitalization starts at K.



   

   

   

Digitalization: Definition and Differentiation from Industry 4.0

What is digitalization?

Digitalization describes the use of digital technologies to optimise and automate processes. In the plastics and rubber industry, this means that production processes, business processes and services are supported and improved by modern IT systems and software solutions.

Difference between digitalization and Industry 4.0

Industry 4.0 is a concept that describes the networking of machines, systems and people through digital technologies in industrial production. While digitalization is a general term for the switch to digital processes, Industry 4.0 is a specific application of these technologies in production. The key elements of Industry 4.0 are:

  • Cyber-physical systems (CPS): Networked machines and systems that exchange data in real time.
  • Internet of Things (IoT): Networking of devices and machines via the internet.
  • Artificial intelligence (AI): Use of algorithms for process control and decision-making.
dof German companies are "basic users" of digitalization technologies. They are characterised by low to medium use.

Source: Fraunhofer ISI

Why is digitalization so important?

Digitalization and Industry 4.0 are not just trends, but necessary developments in order to remain competitive. For the plastics and rubber industry, this means a far-reaching transformation towards more efficient, more flexible and higher-quality production processes. By using modern technologies, companies can strengthen their market position and act in a future-proof manner.

Digitalization starts at K.

Stories & Insights on the Topic of Digitalization

Image: two men standing in front of the display of a large industrial machine; Copyright: Billion SAS

OPC UA significantly simplifies processes

Image: Waste sorting plant; Copyright: hiv360 – sdobe.stock.com

Recycling: AI improves sorting efficiency and material purity
Photo: Detail of a person sitting in front of a laptop with the Ultrasim® simulation competence open; Copyright: BASF SE

Particle foam perfectly distributed thanks to simulation with Ultrasim®
Image: Piles of plastic waste sorted by colour; Copyright: STEINERT

AI-based sorting: the smart way to recycle plastics

What Does Digitalization Mean for Companies?

Digitalization is having a profound impact on companies, particularly in the plastics and rubber industry. It is not only changing the way products are manufactured and services are provided, but is also influencing the entire corporate structure and culture.

Possible applications in the plastics and rubber industry

Digitalization offers numerous potential applications to improve efficiency, quality and flexibility in the plastics and rubber industry. The main areas of application are summarized here with practical examples:

1. Process Optimization and Automation

Production processes can be significantly improved and automated through the use of digital technologies:

  • Automated production lines: Use of robots and networked machines that continuously monitor and adjust production data. Example: A plastics processing plant uses IoT sensors for real-time monitoring to reduce machine downtime and ensure product quality.
  • Predictive maintenance: Predictive maintenance based on data analysis to minimize unplanned downtime. Example: A rubber manufacturer uses sensors to monitor the condition of its machines and carry out maintenance work in good time.

2. Product Development and Quality Assurance

Digital technologies enable faster and more cost-efficient development and product quality assurance:

  • Digital twins: Creation of virtual images of production facilities for simulation and optimization. Example: A plastics manufacturer uses digital twins to test the efficiency of new production lines before they are physically implemented.
  • Additive manufacturing (3D printing): Use of 3D printers for prototyping and small batch production. Example: A company produces individual prototypes from rubber in order to meet customer requirements quickly and flexibly.

3. Supply Chain Management and Logistics

Digitalization improves transparency and efficiency in the supply chain and logistics:

  • Tracking and traceability: Use of RFID tags and IoT technologies to monitor materials and products. Example: A manufacturer of plastic packaging uses RFID tags to track the location and condition of raw materials and finished products in real time.
  • Optimized warehouse management: Automated systems for managing stock levels and material flows. Example: A rubber producer implements a warehouse management system to optimize stock levels and shorten delivery times.

4. Customer Interface and Sales

Digital technologies are also revolutionizing the way companies interact with their customers and market their products:

  • Digital sales platforms: Use of e-commerce and digital marketplaces to market and sell products. Example: A plastics manufacturer uses an online platform to sell customized products directly to end customers and tap into new market segments.
  • Virtual and augmented reality (VR/AR): Use of VR and AR to present products and train customers and employees. Example: A company offers virtual showrooms in which customers can experience products in an interactive 3D environment.

Advantages of digitalization for companies

For companies in the plastics and rubber industry, digitalization not only means a technological change, but also a strategic realignment. By integrating digital technologies, companies can increase their efficiency, improve product quality, operate more flexibly and develop new business models. This is crucial in order to remain successful in global competition and meet the increasing demands of customers.

Increasing Efficiency and Reducing Costs

Improving Product Quality

Flexibility

Sustainability and Resource Efficiency

Digitalization Newsticker

Image: Waste sorting plant; Copyright: hiv360 – sdobe.stock.com
Recycling: AI improves sorting efficiency and material purity
Waste management is undergoing a transformation like never before, thanks to cutting-edge technologies such as artificial intelligence (AI) and machine learning. Companies like PolyPerception are at the forefront of this revolution, redefining how waste is sorted and managed to meet the growing challenges of the industry.
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Image: Piles of plastic waste sorted by colour; Copyright: STEINERT
AI-based sorting: the smart way to recycle plastics
Artificial intelligence and plastics recycling – two concepts that have little in common at first glance, but which form an impressive symbiosis in practice. STEINERT and RE Plano are impressive proof of this. Thanks to AI, they have succeeded in overcoming the challenges of sorting polyethylene and polypropylene, paving the way for innovative recycling solutions.
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Image: red and white industrial plant against a neutral background; Copyright: Wittmann Inc.
"Industrial communication will change”
Industry interview on OPC UA with Dana Ford, Auxiliary Controls Engineer for Material Handling/Auxiliary at Wittmann Inc.
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Image: two men standing in front of the display of a large industrial machine; Copyright: Billion SAS
OPC UA significantly simplifies processes
Industry interview with Georg Kiesl, General Manager at Billion SAS on the spread of the OPC UA standard in the USA.
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PLASTICS and VDMA must work together on OPC UA
Industry interview on OPC UA with Glenn Anderson, Chief Operating Officer at the Plastics Industry Association (PLASTICS) and Thorsten Kühmann, Managing Director of the VDMA Plastics and Rubber Machinery Association
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Image: two hands holding a NIR spectroscopy soloution; Copyright: trinamiX GmbH
Material determination at the touch of a button using NIR spectroscopy
Plastics industry strives to recycle plastics as comprehensively as possible. However, this is not always so easy – especially when different types of plastic are difficult to distinguish visually. This is when near-infrared spectrometers (NIR) come to the rescue, identifying the types of plastic and thus facilitating further processing.
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Image: small, colorful plastic parts enlarged with a magnifying glass; Copyright: SKZ
Digital Recycling Tool: CYCLOPS
An innovative tool called CYCLOPS – Circularity Optimisation for Plastics has set itself the task of closing the gap between the need for information and the supply of recycled materials. By providing comprehensive data and assessments, it helps companies to make more sustainable decisions and organise their production processes in a more environmentally friendly way.
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Photo: Detail of a person sitting in front of a laptop with the Ultrasim® simulation competence open; Copyright: BASF SE
Particle foam perfectly distributed thanks to simulation with Ultrasim®
BASF SE's Ultrasim® simulation portfolio for plastics applications is now also available for manufacturing processes of components made of particle foam components. The application starts with the expanded thermoplastic polyurethane (E-TPU) Infinergy® and expands BASF's proven simulation portfolio for plastics innovations
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Digital compass to sustainability: lifecycleValueCalculator analyses economic and ecological potentials
Profitability and sustainability are not opposites – on the contrary! KraussMaffei's lifecycleValueCalculator proves it: the digital tool calculates the current status of plastics processors' products and shows them their individual potential for improvement. This enables them to increase their production efficiency and achieve their ecological goals at the same time.
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The one stop shop for digital solutions: ENGEL integrates software company TIG
ENGEL is gradually expanding its customer portal e-connect into a production portal. In addition, a solution from the inject 4.0 family for bidirectional data exchange between simulation and injection molding machine has been expanded and now also works with MOLDEX3D.
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Reifenhäuser relies on new "Circular Plastics Traceability" Guideline by using digital product passports from R-Cycle
The Reifenhäuser Group uses R-Cycle, a digital product passport for plastics based on GS1 standards, to enable its customers to trace products. This facilitates data management in the manufacturing process and promotes the recycling of plastic packaging.
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Productivity management via app: capturing and understanding machine data
Efficient work only works when everything runs smoothly – also on the shop floor. But how do I know how busy and productive my machines are at the moment? This requires data that reflect reality, but which is often still lacking today. ENLYZE has developed an analysis platform that can close this gap and make production more efficient.
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Circular Collaboration Platform: for more recyclates in food packaging
The share of recycled material in plastic products is growing. The exception: food packaging. The requirements for the quality of the material for food contact are high, but in the case of recyclates there is still often a lack of corresponding information today. The project COPPA wants to create transparency in this area – with an open digital platform.
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LANXESS software calculates carbon footprint for Group's own products
With the "Product Carbon Footprint Engine" developed by LANXESS, the CO2 footprint can be calculated automatically for the Group's products. With this innovation, the speciality chemicals company aims to help its customers achieve their sustainability goals.
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Automated simulation software creates a world map of polymer properties
"Materials informatics (MI), a new branch of materials research that combines materials data with data science, is gaining traction," said co-corresponding author Yoshihiro Hayashi, assistant professor, Institute of Statistical Mathematics in the Research Organization of Information and Science (ROIS).
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Plastics industry meets Metaverse: igus presents products in virtual reality
Studies show that we are up to nine times more likely to remember something we have experienced in virtual reality. This knowledge can also be interesting for the plastics industry. With the iguversum, igus has created a digital space in which the manufacturer's products can be discovered. In the future, engineering projects will also be carried out there.
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Artificial Intelligence in the Plastics and Rubber Industry

Artificial intelligence (AI) is improving the plastics and rubber industry through accurate forecasting and efficient process control: machine learning can continuously monitor and adapt production processes to maximize quality and efficiency. AI can also detect anomalies and errors at an early stage, reducing downtime and increasing productivity.

Companies that are already using AI-based solutions in manufacturing processes:

Source: MHP

Digitalization and Circular Economy

Digitalization plays a central role in the implementation of the circular economy in the plastics and rubber industry.

Digital solutions enable ...

  • Efficient monitoring and optimization of raw material and product flows
  • Reduction of waste and conservation of resources
  • Better traceability and reuse of materials
  • Promotion of sustainable production cycles

By combining digitalization and the circular economy, companies in the plastics and rubber industry can achieve their sustainability goals and increase their competitiveness at the same time.

Image: small, colorful plastic parts enlarged with a magnifying glass; Copyright: SKZ
Digital Recycling Tool: CYCLOPS
An innovative tool called CYCLOPS – Circularity Optimisation for Plastics has set itself the task of closing the gap between the need for information and the supply of recycled materials. By providing comprehensive data and assessments, it helps companies to make more sustainable decisions and organise their production processes in a more environmentally friendly way.
Read more
Image: Sorting belt with plastic bottles. Two employees can be seen out of focus in the background; Copyright: envato
Sustainability thanks to the circular economy
How does the circular economy work? Focus on sustainable practices and environmental benefits.
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Digital reusable cup from Vytal and PepsiCo
Vytal and PepsiCo are taking reusable tableware to a new level in their cooperation. With individual IDs for each cup, which can be read using a QR code or RFID tag, efficiency at large events is increased enormously. The technology not only optimises the return of the cups, but also the entire recycling process, thus making an important contribution to the Circular Economy.
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Photo: Thomas Philipon, CEO of TotalEnergies Corbion and Suvi Haimi, CEO and Co-founder of Sulapac; Copyright: private
Pioneering sustainable solutions in the cosmetic industry
TotalEnergies Corbion and Sulapac have joined forces to advance sustainable practices in the cosmetics sector, emphasizing the integration of recycled and biodegradable materials into product packaging, fostering a more eco-responsible industry.
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Renewable plastic for workboat hulls
Aquaculture takes a sustainable leap forward with the unveiling of a groundbreaking workboat hull constructed from renewable plastic. Borealis and AKVA group will introduce this innovation in Mo i Rana, Norway, in Spring 2024, marking a significant milestone for circularity in marine technology.
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AI in the Plastics Industry: Sustainability & Innovation
AI is revolutionising modern industry. Thanks to it, complex processes can be automated or efficiency increased. In the plastics industry, AI not only plays a decisive role in the optimisation of production processes and the development of new materials. It also enables more precise waste sorting and therefore better recycling – a benefit for the environment!
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Image: Recyclates; Copyright: Cirplus
Digital marketplace as a driver for the Circular Economy
The forthcoming EU packaging regulation is casting its shadow: minimum quotas for recyclates are putting the plastics industry under pressure. Cirplus presents a digital platform that not only makes the recyclate market transparent, but also enables real-time coordination between the players.
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Repsol strengthens its alliance with Pontegadea through a 618 MW renewable portfolio
Repsol has formed a new alliance with Pontegadea, incorporating them as a partner with a 49% stake in a portfolio of renewable assets valued at €740 million. This partnership strengthens Repsol's strategy of bringing in investors to accelerate their renewable energy goals, which include reaching 6,000 MW of installed generation by 2025 and 20,000 MW by 2030.
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Circular Polymers by Ascend and ReDefyne experts highlight expanded options for post-consumer recycled nylons, PET and PP
Experts from Ascend, a leader in recycling post-consumer carpet, and ReDefyne highlight new opportunities for recycled nylon, PET and PP. Their proprietary process allows them to convert end-of-life carpet into feedstocks for materials used in various finished goods, including automobiles and household appliances.
Read more
Image: Woman in a supermarket taking a carton of milk from the shelf; Copyright: RossHelen
Digital compass to sustainability: lifecycleValueCalculator analyses economic and ecological potentials
Profitability and sustainability are not opposites – on the contrary! KraussMaffei's lifecycleValueCalculator proves it: the digital tool calculates the current status of plastics processors' products and shows them their individual potential for improvement. This enables them to increase their production efficiency and achieve their ecological goals at the same time.
Read more
Image: blurred detail of a person in a black suit holding a pen. In front of her is a laptop and papers with diagrams; Copyright: donut3771
Reifenhäuser relies on new "Circular Plastics Traceability" Guideline by using digital product passports from R-Cycle
The Reifenhäuser Group uses R-Cycle, a digital product passport for plastics based on GS1 standards, to enable its customers to trace products. This facilitates data management in the manufacturing process and promotes the recycling of plastic packaging.
Read more

How Will Digitalization and Industry 4.0 Affect the Work of the Future?

Digitalization and Industry 4.0 are having a profound impact on the world of work and will continue to change it in the coming years:

Routine tasks will be automated.

New professions will emerge.

Working models will become more flexible.

Qualification requirements will change.

Employees will be lifelong learners.

Skills shortage:

of companies state that the introduction of Industry 4.0 technologies is being delayed as a result.

Source: MHP

Digitalization starts at K!

At K 2025 you will find everything to do with Digitalization ...

  • the latest technologies such as artificial intelligence (AI), augmented reality (AR) and apps.
  • Advice on digital solutions for your business.
  • Discussions and exchanges with experts on the topics of Industry 4.0, the networked value chain, IoT and more.

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