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Robotic arms in a modern electronics factory as a symbol of digitalisation in the plastics industry - K 2025

Embracing Digitalisation

Digitalization in the Plastics Industry: Definition and Difference from Industry 4.0

How Digital Transformation Is Driving Innovation and Sustainability in the Plastics Sector

Impressions of the K trade fair on the subject of digitalisation

Experience the digital revolution in the plastics industry – live at K!

The digitalization of the plastics and rubber industry is fundamentally reshaping production processes, enabling real-time data analysis, predictive maintenance, and smart manufacturing. At the heart of this transformation lies the potential to reduce resource consumption, increase efficiency, and develop sustainable solutions that meet global market demands.

K is the leading trade fair where digital transformation becomes tangible: from networked machinery and Industry 4.0 applications to innovative software solutions for the plastics sector. For exhibitors and visitors alike, K offers a first-hand look at how the digital revolution is redefining business models, supply chains, and customer interaction in the plastics industry.

Digitalisation starts at K – and with it, the future of plastics.



   

   

   

Digitalisation of the Plastics and Rubber Industry

What Is Digitalisation?

Digitalisation refers to the use of digital technologies to optimize, automate and connect processes across production and business workflows.
In the plastics and rubber industry, this transformation affects everything from manufacturing and logistics to customer service and product development. Digitalisation enables real-time data usage, transparent process control, and efficient resource management – all key aspects for companies that aim to stay competitive in a dynamic market.

Digitalisation vs. Industry 4.0 – What’s the Difference?

While the terms are often used interchangeably, there is a key distinction between Digitalisation and

 

Industry 4.0.

  • Digitalisation is the overarching process of converting analog into digital and integrating IT systems into all business areas.
  • Industry 4.0, on the other hand, is a specific subset of Digitalisation, focused on smart, automated, and connected industrial production.

Key technologies of Industry 4.0 in the plastics industry include:

  • Cyber-Physical Systems (CPS): Machines and production systems that interact and exchange data autonomously.
  • Internet of Things (IoT): Intelligent networking of devices and machinery along the entire value chain.
  • Artificial Intelligence (AI): Algorithm-based optimization of processes, predictive maintenance, and improved decision-making.

 

Together, these technologies represent the digital revolution in the plastics industry, paving the way for flexible, data-driven, and sustainable production systems.

of German companies are "basic users" of digitalisation technologies. They are characterised by low to medium use.

Source: Fraunhofer ISI

Why Digitalisation Matters in the Plastics Industry

The digital transformation is more than a trend – it’s a critical factor for future-proof success. In the plastics and rubber sector, Digitalisation enables:

  • Greater process efficiency and automation
  • Sustainable production through better resource control
  • Faster innovation cycles and increased product quality
  • Resilience in global supply chains and fluctuating markets

By embracing digital technologies, companies gain a competitive advantage and actively contribute to more sustainable, transparent, and intelligent value creation.

 

Digitalisation starts at K – the world’s leading trade fair for plastics and rubber.

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Digital Transformation in the Plastics Industry – Trends, Insights & Case Studies

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 Digitalisation Mean for the Plastics Industry?

Digitalisation of the plastics and rubber industry is transforming not just production workflows, but the very structure of companies. From automated manufacturing to digitally enhanced customer service, digital transformation is reshaping corporate culture, decision-making, and innovation capabilities.

For companies in the plastics sector, this shift opens new opportunities to streamline operations, reduce costs, and remain competitive in global markets. Embracing digital tools and data-driven systems is becoming a strategic necessity.

Use Cases and Applications of Digitalisation in the Plastics Industry

The digital revolution in the plastics industry enables a wide range of applications that boost efficiency, quality and flexibility. Key application areas include:

 

  • Smart Production: Real-time monitoring and adjustment of machinery using IoT sensors and AI.
  • Predictive Maintenance: Minimizing downtime with machine learning–based analysis of wear and usage data.
  • Digital Supply Chains: Transparent, automated logistics and inventory management.
  • Quality Control with AI: Automated defect detection and process optimization.
  • Custom Manufacturing: Flexible production systems that allow for individualized product designs and small batch sizes.
  • Energy Monitoring & Sustainability: Optimized resource consumption through intelligent systems.

 

These examples show how digital transformation can be practically applied to improve performance and sustainability in plastics manufacturing.

1. Process Optimization and Smart Automation

Digitalisation enables significant improvements in process efficiency and automation across the plastics and rubber industry.

  • Automated Production Lines: By using networked machines and industrial robots, manufacturers can monitor and optimize processes in real time.
    Example: A plastics processing company leverages IoT sensors to reduce machine downtime and ensure consistent product quality.
  • Predictive Maintenance: With data-driven maintenance strategies, unplanned downtime is minimized, increasing overall equipment efficiency (OEE).
    Example: A rubber producer uses intelligent sensors to detect wear early and schedule maintenance proactively.
These smart technologies form the backbone of Industry 4.0 in the plastics industry, enabling scalable, resilient, and future-ready production environments.

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

The digital transformation supports faster, cost-effective product development and reliable quality assurance.

  • Digital Twins: Virtual replicas of machines or production lines allow for detailed simulation and optimization before real-world implementation.
    Example: A plastics manufacturer uses digital twins to test new plant configurations and reduce ramp-up times.
  • Additive Manufacturing (3D Printing): Flexible prototyping and small-batch production reduce development cycles and improve customization.
    Example: A rubber processor creates tailor-made prototypes using 3D printing to fulfill specific customer needs.
These technologies enhance innovation cycles and make production more adaptive and customer-oriented.

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. Transparent Supply Chains and Digital Logistics

Digitalisation in supply chain management leads to more transparency, traceability, and efficiency in logistics operations.

  • Real-Time Tracking and Traceability: RFID tags and IoT technologies enable seamless tracking of materials and finished goods.
    Example: A plastic packaging supplier uses RFID to monitor inventory, improving logistics and reducing waste.
  • Smart Warehouse Management: Automated systems manage inventory levels, predict demand, and streamline order fulfillment.
    Example: A rubber manufacturer integrates a warehouse management system to optimize stock control and delivery speed.

By connecting the entire value chain, companies increase agility and responsiveness in volatile markets.

Digitalisation 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. Digital Customer Interaction and Smart Sales Solutions

The digital revolution in the plastics industry is also transforming customer relationships and sales strategies.

  • E-Commerce and Digital Marketplaces: Companies reach new customer segments through personalized online sales channels.
    Example: A plastics manufacturer sells customized components via a digital platform, improving customer experience and market reach.
  • Virtual & Augmented Reality (VR/AR): Immersive technologies support product presentations, training, and service.
    Example: A company offers virtual showrooms and AR-guided product training to enhance customer engagement and reduce time-to-market.

These tools support customer-centric innovation and open up new business models in a digitalized market environment.

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 Digitalisation for the Plastics and Rubber Industry

For companies in the plastics and rubber industry, Digitalisation is far more than just a technological upgrade – it marks a strategic transformation that affects every level of the organization. By implementing digital technologies such as IoT, AI, and data analytics, businesses can significantly improve their efficiency, enhance product quality, and increase their ability to respond flexibly to changing market demands.

At the same time, Digitalisation opens the door to innovative, data-driven business models that help companies remain competitive in an increasingly globalized industry. The ability to act with greater speed, precision, and customer focus becomes a decisive advantage. In this way, digital transformation evolves from a technical initiative into a critical success factor for future-oriented companies in the plastics sector.

Increasing Efficiency and Reducing Costs

Improving Product Quality

Flexibility

Sustainability and Resource Efficiency

News and Updates on the Digitalisation of the Plastics Industry

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Artificial Intelligence in the Plastics and Rubber Industry

Artificial Intelligence (AI) is playing an increasingly important role in the digital transformation of the plastics and rubber industry. By using machine learning algorithms, production processes can be continuously monitored, analyzed and optimized in real time to ensure maximum efficiency and product quality.

AI systems are capable of detecting anomalies, predicting errors before they occur, and automatically adjusting machine parameters. This reduces unplanned downtime, improves resource utilization and significantly increases overall productivity. In combination with IoT technologies and smart data analysis, AI forms a central pillar of Industry 4.0 in plastics manufacturing.

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

Source: MHP

How Digitalisation is driving the Circular Economy in the Plastics Industry

Digitalisation plays a central role in implementing the circular economy within the plastics and rubber industry. Smart technologies and connected systems enable companies to manage resources more efficiently and design sustainable production cycles.

By using digital solutions, companies can:

  • Monitor and optimize raw material and product flows in real time, reducing inefficiencies across the entire value chain.
  • Reduce waste and conserve resources through data-driven process control and automated adjustments.
  • Improve traceability and facilitate the reuse of materials, enabling closed-loop systems and higher recycling rates.
  • Promote sustainable production cycles by integrating digital planning, monitoring, and feedback mechanisms into all phases of manufacturing.

The synergy between digital transformation and the circular economy strengthens both environmental responsibility and economic performance. Companies that embrace this connection position themselves as innovation leaders in a resource-efficient plastics industry.

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How Digitalisation and Industry 4.0 Are Shaping the Future of Work in the Plastics Industry

Digitalisation and Industry 4.0 are fundamentally transforming the world of work – especially in the plastics and rubber industry. Intelligent machines, data-driven systems and connected production environments are redefining how, where and by whom work is done.By using digital solutions, companies can:

 

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

Digitalisation starts at K!

It all starts at K

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

  • 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.

The countdown to K 2025 is on!

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Hot Topics of K 2025

The Power of Plastics! Green – Smart – Responsible

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Shaping the Circular Economy

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Hot topic digitalisation at the K 2025

Embracing Digitalisation

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