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Beverage Packaging Sustainability Accelerated by Returnable Innovations

Yi-chun
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Beverage Packaging Sustainability Accelerated by Returnable Innovations

Beverage Packaging Sustainability Accelerated by Returnable Innovations

Sidel supported Grupo GEPP, PepsiCo’s exclusive bottler in Mexico, to install expanded returnable PET and glass bottling lines to meet growing consumer demand and sustainability goals.

Grupo GEPP operates 44 production facilities dedicated to the manufacturing and distribution of renowned international brands, including Gatorade, Lipton, Pepsi, and 7Up and owns the brands Epura and Garci-Crespo. With a workforce exceeding 46,000 employees, Grupo GEPP stands as one of the largest private sector employers in Mexico. In 2014 and 2021, PepsiCo awarded GEPP the global ‘Bottler of the Year’ award.

In line with its strong commitment to sustainability, GEPP adopted PepsiCo’s strategy in 2018 to reduce the use of virgin plastics.

Reusability plays a key role in supporting PepsiCo’s broader environmental goals, including reducing first-use plastic per serving by 50%, increasing returnable packages from 10% to 20% by 2030 and achieving net zero emissions by 2040.

Returnable PET and glass lines – delivering greater flexibility and eco-friendly solutions

GEPP chose to partner with Sidel, recognising the company’s proven expertise in implementing returnable bottling solutions and the performance advantages of integrated technologies.

In 2018, Sidel supported with the installation of a partial returnable glass bottle (RGB) line at GEPP’s Puebla facility. Building on this success, a combined returnable PET and glass line was commissioned in Apodaca in 2019. In 2020, Sidel delivered a complete returnable PET line in Guadalajara, designed to handle 2L, 2.5L, and 3L formats, with built-in capability to accommodate RGB in the future. And 2021, Sidel also delivered a new returnable PET line and glass line in Merida.

The returnable PET and glass lines feature the innovative EvoFILL Glass, an advanced level probe filler that combines optimal hygienic conditions with greater flexibility, and the Hydra bottle washer, which enhances washing effectiveness while reducing chemical and water consumption, as well as the total cost of ownership (TCO).

“This ongoing collaboration exemplifies how long-term partnerships—grounded in reliability, service excellence, and technical knowledge-sharing—can enhance operational efficiency, support sustainable business practices, and help customers successfully navigate the evolving demands of the beverage industry,” comments Ascención Sánchez, Sidel’s Account Manager.

Prioritising sustainability

GEPP has been a pioneer and a key player in the creation of a true circular plastic economy in Mexico. Through ECOCE, a non-profit association that promotes packaging recycling, GEPP has contributed to collecting and recovering 6 out of every 10 bottles produced by the industry.

This recovery rate – currently the third highest in the world – has enabled GEPP to significantly increase the incorporation of recycled PET (rPET) used within its packaging, reaching 26% by the end of 2023, while dramatically reducing the use of PET resin.

The reduction in the use of raw materials is also driven by the growth of GEPP’s returnable bottle portfolio. The company has continued expanding its capabilities to offer consumers beverage options in returnable glass bottles and plastic returnable bottles.

Through its partnership with Sidel to strengthen its returnable packaging operations, this has enabled GEPP to capture nearly 30% of the incremental PET volume achieved by the business, thereby avoiding the use of virgin resin.

Between 2018 and 2023, GEPP achieved a 73.3% increase in the volume of returnable packaging in PET and glass, growing from a baseline of 100% in 2018 to 173.3% in 2023[1]. This growth reflects the company’s continued investment in sustainable packaging alternatives and its commitment to reducing the use of raw materials.

In 2018, GEPP launched the universal returnable glass bottle that makes beverage production more efficient and agile, while also contributing to the reduction and recycling of materials, mitigating the impact on the environment.

https://www.sidel.com/en

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Driving Interior Efficiency with Physical Foaming Tech

Arun Joy
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Driving Interior Efficiency with Physical Foaming Tech

Driving Interior Efficiency with Physical Foaming Tech

At K 2025, ENGEL is presenting a state-of-the-art manufacturing solution from its WINTEC brand for interior automotive components. At the heart of the exhibit is the t win 6500 twoplaten injection moulding machine with 6500 kN clamping force, equipped with MuCell technology for physical foaming. This combination enables the cost-effective production of a B-pillar trim made of mineral-filled polypropylene in just 50 seconds, while achieving significant material savings.

MuCell works with nitrogen or carbon dioxide, which is introduced into the plastic melt. The screw geometry, specially optimised for MuCell, ensures uniform gas distribution, resulting in a fine cell structure within the mould. The result is a lighter component with outstanding dimensional stability and visible surface quality – ideal for high-end automotive interior parts.

30% less material, same stability: MuCell technology enables cost-efficient lightweight design for automotive interiors.

The exhibit part has a shot weight of around 290 grams and is moulded from SABIC’s polypropylene grade F9015. The tool from SIMOLDES demonstrates that complex interior components can be manufactured more sustainably and cost-effectively – without compromising on design. The use of MuCell reduces both weight and material consumption, resulting in a lasting reduction in unit costs.

While ENGEL stands for tailored solutions that meet the highest demands in precision, efficiency and digitalisation, WINTEC offers proven standard solutions with ENGEL DNA. ENGEL primarily targets customers seeking high levels of innovation and customisation, whereas WINTEC delivers cost-optimised, readily available machines for reliable, smart applications. Both brands guarantee high quality, with WINTEC benefitting from ENGEL’s extensive expertise.

The t-win from WINTEC is distinguished by its robust two-platen design. Short-stroke pressure pads enable short cycle times, while a synchronous locking system and servo-hydraulic drive ensure fast and energy-efficient operation. Its high energy efficiency, compact footprint and optimised maintenance access reduce overall operating costs and ensure a fast return on investment.

WINTEC injection moulding machines are equipped with the intuitive C3 control unit, which ensures clear process management with high performance. The new model of a fully integrated viper 20 linear robot handles part removal and relieves the workload on operating personnel. The close integration of robot and machine within a single control system enhances process stability and shortens cycle times by optimising motion sequences.

The digital assistance system iQ hold control supports the optimisation of the holding pressure time during initial process setup. With just one click, it automatically determines the sealing point for the respective component. The result is a significant time saving and optimised cycle times without manual effort, while providing reproducible values.

During ongoing production, the integrated digital assistance system iQ weight control responds in real time to changes in melt viscosity. For each cycle, it analyses the filling behaviour and automatically adjusts the switchover point to ensure consistent part weight. This enables scrap rates to be reduced by up to 85 percent and improves process reliability – a crucial benefit when dealing with fluctuating batch properties.

The ENGEL iQ process observer is also integrated into the production cell. This digital assistance system continuously monitors a wide range of machine and process parameters throughout the injection moulding process, detects deviations at an early stage and automatically provides concrete recommendations for action. As a result, it helps to further increase process stability, ensure consistent part quality and sustainably improve the productivity of the system.

With this fully automated production solution, WINTEC demonstrates what modern interior part manufacturing can look like: reduced material consumption, low energy usage, and consistent performance and quality. Injection moulders benefit from short cycle times, durable machine components, and a compact system solution that can be easily integrated into existing production lines. WINTEC offers efficient plug-and-play solutions with high availability, delivering excellent value for money without compromising performance – a clear competitive advantage for its customers.

https://www.engelglobal.com/

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An Executive Interview on the road to K 2025 with Mr. Marcel Moeller, Global Branch Manager Plastics Industry at Baumüller Nürnberg GmbH, Sustainability and circular economy are absolutely essential

Nora Szabó
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An Executive Interview on the road to K 2025 with Mr. Marcel Moeller, Global Branch Manager Plastics Industry at Baumüller Nürnberg GmbH, Sustainability and circular economy are absolutely essential

An Executive Interview on the road to K 2025 with Mr. Marcel Moeller, Global Branch Manager Plastics Industry at Baumüller Nurnberg GmbH, Sustainability and circular economy are absolutely essential

Mr. Moeller, how does the electrification trend within the plastics industry contribute towards sustainability?

The excellent efficiency of electric drive systems reduces energy consumption and, as a result, CO2 emissions. This correlates with optimised material usage, and also helps customers to manufacture their products globally, and with high process reliability. Servo hydraulics is a good example. Here, we combine the very high-power density of hydraulic power transmission with the control quality and dynamics of energy-efficient electric drive systems, which, when combined with intelligent software, results in energy savings. Another example is the plasticising or screw drive, which is often one of the main energy consumers. Replacing the hydraulic drive with an electric drive saves a vast amount of energy. Productivity can also be increased, depending on the machine cycle or end product. We are also witnessing the electrification of the so-called clamping drive in injection moulding machines, but also in blow moulding machines, where energy can be recovered during the braking phase.

The need for energy efficiency is not as pressing in other parts of the world as it is in Europe. Is the trend towards electrification equally strong in other regions?

High energy costs are not the driving factor everywhere, but they are of course an issue. The stability of the energy supply and possible subsidy programmes are strong regional factors of influence. In Europe, the demand for energy-efficient drives is a consequence of high industrial electricity prices. In the US, developments are fuelled by CO2 emission savings to a greater degree. And in Asia, it is not necessarily energy costs, but rather the stability and availability of energy that are the catalyst in terms of the demand for energy-efficient drives.

Can systems generally be retrofitted with electric drives at all stages, or is this only possible in new systems?

Machines in the field can be retrofitted; this is a very good way to improve the efficiency of existing plants, especially where there is a lack of investment security. I would like to cite servo hydraulics again as an example, where we offer such retrofit solutions to end users in coordination with our machine manufacturing customers.

Things have quietened down around the topic of circular economy. How do you rate its significance at present?

You can already tell from the announcements about K that things have calmed down somewhat. Other topics are coming back into focus alongside sustainability: technological innovations, digitalisation and increasing productivity. Behind this is the need to arm ourselves against increasingly tough competition from Asia, but the issue of sustainability or the circular economy is absolutely essential. Global demand for plastics rose to 400 million tonnes in 2023, and is set to more than double by 2050. This shows how important and valuable plastics are as a raw material: for e-mobility, and for medical technology as a result of the sharp rise in online care and mobile health solutions. To achieve the ambitious climate targets, we have no other solution than the circular economy. Currently, only around ten percent of demand is met by recycled plastics, perhaps 15 percent in Germany. There is still enormous room for improvement, but in our opinion, this is a great opportunity to take on a pioneering role through technological innovation, and to expand or secure competitiveness.

What will playing this pioneering role actually involve?

The basic prerequisite is, of course, a recyclable product design, and the efficient collection and sorting of plastic waste. Recyclates must have at least the same conditions as virgin materials in terms of price and availability. I think that since K22, a lot of innovations have emerged in the field of machinery that can ensure or achieve recyclability. However, the necessary framework conditions are not yet in place. There is still significant potential for optimisation. And, last but not least, there is the issue of regulation, which should ensure fair competition, and not slow down progress or tie up time and resources.

How far has mechanical engineering advanced in terms of AI, especially in drive systems?

Digitalisation is an important tool for our customers to optimise productivity. One example is simulation software, which can be used to design drive components in a digital twin before they are implemented in a real machine. At Baumüller, we are pushing the topic of AI and therefore also our intelligent drive-based solutions, such as an injection regulator for injection moulding machines, energy monitoring, and a shock detection function for plasticising and shredding drives. Another example is communication interfaces in production networks with peripheral devices, or with upstream and downstream value-added stages.

How do you assess the importance of K as a venue in view of the continuing difficult environment?

K is an absolutely international trade fair, which sets it apart from all others. It is an important source of inspiration for innovation and sustainable solutions, and ultimately also a driver for new business development. This trade fair is extremely important as an international platform – especially in view of the current economic situation in Europe and other regions, which is not exactly ideal. Everyone is represented there, including the growth markets in Asia, which is why we’re looking forward to stimulating discussions with customers and interested parties.

https://www.vdma.eu/

#K2025 #Modernplasticsindia #Pasticsnews #ModernPlasticsIndiaMagazine
#PrintPublication #Modernplasticschina

Gravure Printing Industry Gains New Technical Expertise through Association

Nora Szabó
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Gravure Printing Industry Gains New Technical Expertise through Association

Gravure Printing Industry Gains New Technical Expertise through Association

The Global Rotogravure Association (GRA) is pleased to welcome DMA INNOTEC GmbH as a new member. As a specialist in electromechanical cylinder engraving systems, DMA INNOTEC strengthens GRA’s network with its deep technical expertise and commitment to innovation.

Based in Germany and Taiwan, DMA INNOTEC offers high-performance engraving machines tailored for gravure and special applications. Their product portfolio includes both standard and customized solutions, supported by in-house software and intuitive user interfaces. With more than three decades of industry experience, DMA INNOTEC has built a strong reputation for quality, flexibility, and customer-focused service. DMA offers three product series with worldwide installations, establishing the company as a key contributor to today‘s electromechanical engraving technology.

The company supports clients across a range of sectors, including packaging, security, decorative printing and maintains close partnerships with equipment manufactures and international engravers. Sustainable innovation, reliable service, and constructive cooperation are keys to its long-term customer relations

“We are delighted to welcome DMA INNOTEC to our association,” said Stefani Dhami, head of GRA. “Their membership expands our portfolio to include Taiwan — another important step in our mission to grow the Global Rotogravure Association into a truly international platform.”

www.rotogravure.org

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A Vision of Sustainability Comes Alive with CARES

Anagha Salvi
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A Vision of Sustainability Comes Alive with CARES

A Vision of Sustainability Comes Alive with CARES

  • Envalior today announces the launch of Envalior CARES, its organization-wide commitment to addressing the environmental and social impacts of its business through concrete sustainability ambitions, targeted actions, and partnerships.
  • The company has updated its greenhouse gas emissions targets following an adjustment to the baseline measurement year. This has led to revised Scope 1 and 2 emissions reduction goals for 2030.
  • Examples of how the company puts Envalior CARES into practice will be featured at K 2025 and in its upcoming Sustainability Report, including a wide range of bio-based and recycled-based Engineering Materials.

Envalior, a global leader in Engineering Materials, is strengthening its sustainability roadmap to further improve transparency, accountability, and performance across key environmental and social areas. These efforts are organized under the umbrella of Envalior CARES, a strategic sustainability approach built on three pillars: Low CArbon, Sustainable REsources, and Social Responsibility. Through this framework, Envalior supports its customers in their sustainability transition while advancing its own goals, ensuring the greatest possible positive impact for all stakeholders and society at large.

Envalior CARES was developed to drive sustainable change in the Engineering Materials industry, providing an ambitious and pragmatic roadmap. Key organizational frameworks and strategic commitments already in place include: Scope 1 and 2 greenhouse gas (GHG) emissions targets for 2030; dedicated teams for its portfolio of bio- and recycled-based alternatives; a roadmap to having all European production sites audited according to the Operation Clean Sweep (OCS) pellet-loss prevention standard; and an ambitious global safety program.

“Our dedication to sustainability isn’t just part of our strategy – it’s part of who we are and a key company value. At Envalior, we see this as an opportunity to lead the change and to create long-term value for all our stakeholders,” says Calum MacLean, CEO of Envalior.

Low Carbon: Updated greenhouse gas (GHG) emissions targets

As part of the Low Carbon pillar of Envalior CARES, the company has revised its Scope 1 and 2 GHG emissions targets. The baseline year has been updated to 2024 to improve data transparency and allow for more accurate tracking of progress. Between 2016 and 2024, Envalior’s predecessor companies achieved a 65% reduction in Scope 1 and 2 emissions through operational improvements and procurement measures. Building on this achievement, Envalior now aims to cut emissions by a further 35% from 2024 to 2030.

The reductions will be achieved through a range of initiatives, including Envalior’s commitment to sourcing 100% of its electricity from renewable sources by 2030, the launch of on-site emissions reduction projects, and the transition to low-carbon heat sources. The next step is to develop a decarbonization roadmap extending beyond 2030, ensuring alignment with the most scientifically robust and actionable global climate objectives. Once this is in place, further concrete targets for Scopes 1 and 2 will be communicated, and Scope 3 targets will be incorporated into Envalior’s climate roadmap.

Sustainable Resources: Discover Envalior’s solutions at K 2025

The Sustainable Resources pillar of Envalior CARES focuses on conserving the valuable raw materials used in our products and making sure they are used as efficiently as possible. This involves developing more sustainable products and taking a holistic view of their entire life cycle. Such an approach plays a key role in reducing the environmental impact of both Envalior and its customers.

Visitors to K 2025, the world’s leading trade fair for plastics and rubber (October 8 to October 15), will be able to experience Envalior’s latest sustainable innovations firsthand. These include a wide selection of ISCC PLUS-certified materials. Compared to conventional fossil-based alternatives, these materials can offer an improved environmental profile, including a lower carbon footprint, without compromising performance or requiring major process changes for customers. These “drop-in solutions” are possible thanks to Envalior’s strong supply chain, backward integration in key monomers, and excellent polymerization capabilities.

For example, sustainable PA6 alternatives for electrical and electronic (E&E) applications, and packaging, will be on display at K 2025. These include a Durethan ECO and a Durethan BLUE grade, containing up to 90% ISCC PLUS-certified bio-based and recycled content (by mass balance attribution). Envalior’s Stanyl B-MB PA46 range is also ISCC PLUS-certified, with bio-based content by mass balance attribution. This generates a carbon footprint up to 50% lower than the fossil-derived original grade. Together with its customers and partners, Envalior is supporting the creation of more sustainable solutions across industries

Social Responsibility: Driving industry-wide progress through partnerships

The Social Responsibility pillar of Envalior CARES is dedicated to ensuring the safety and well-being of our people and supports several social initiatives in local communities. Envalior’s operations and processes are regularly reviewed to ensure they comply with global standards. By adhering to international human rights standards and conducting regular impact assessments, Envalior ensures transparency and accountability in all its operations. Aligning with both industry-specific and global sustainability initiatives is important for Envalior to maintain transparency as it works toward this goal. The company recently became a signatory of the ICCA Responsible Care Global Charter. This initiative unites leading players in the chemical industry to promote the responsible management of chemicals and encourage sustainable growth around the world. Accurate reporting is a cornerstone of the program, ensuring that signatories demonstrate their ongoing commitment to improving health, safety, and environmental performance. Since 2024, Envalior has also been a signatory of the United Nations Global Compact (UNGC), submitting its first mandatory Communication on Progress (CoP) in July this year.

www.envalior.com

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Industry Experts Share Insights During Live Machinery Runs at K 2025

Lim Hng Kiang
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Industry Experts Share Insights During Live Machinery Runs at K 2025

Industry Experts Share Insights During Live Machinery Runs at K 2025

German machine manufacturer and flexible packaging specialist Windmöller & Hölscher (W&H) will exhibit at K 2025 in Düsseldorf, Germany, from October 8–15, as well as at its In-house EXPO at company headquarters in Lengerich. Highlights include a new development for MDO lines, solutions for easier machine operation, and a range of sustainable packaging applications. A special highlight: W&H will feature two running machines at its booth, with live demonstrations in extrusion and printing.

W&H will be present in Düsseldorf with its 1,100 sqm booth in Hall 17, Booth A57. “By showcasing our VAREX II blown film extrusion line and the ALPHAFLEX flexo printing machine at our booth, we aim to make a statement. The future of packaging production is becoming increasingly connected, and this connection is deeply rooted in our company,” says Dr. Sascha Witt, Chief Sales Officer at W&H.

Both machines will run live demonstrations three times a day, showcasing the latest developments designed to make everyday production simpler, more stable, and more efficient. In addition to these technical innovations, W&H will present a range of advanced product applications focusing on sustainable packaging solutions.

Also present at the booth will be experts from GARANT, the specialist in machinery for paper packaging, as well as AVENTUS the expert for packaging of form-fill-seal (FFS) bags and big bags.

In-house EXPO in Lengerich with 9 running machines and MDO innovation

During K, W&H will also host its In-house EXPO at the company’s 10,000 sqm Technology Center in Lengerich, located just two hours north of Düsseldorf. “We are especially looking forward to presenting EXPO visitors with a revolutionary innovation on our MDO lines that not only greatly reduces neck-in and scrap, but also significantly enhances quality, consistency, flatness, and processability,” highlights Witt.

In total, nine machines will be running live, with two additional machines available for hands-on technical discussions. Featured technologies include blown film extrusion, cast film extrusion, flexographic and rotogravure printing for paper and plastic packaging, as well as the Digital Printing Concept presented at drupa 2024.

Shuttle buses will run three times daily between Düsseldorf and W&H headquarters; seats can be reserved during registration.

“K is the event where the plastics industry meets. It’s our time to welcome the world — to our booth and to our headquarters. We can’t wait to do so!” says Dr. Sascha Witt.

https://www.wh.group/int/en/

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Unlocking Plastics Industry Potential at K-2025

Arun Joy
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Unlocking Plastics Industry Potential at K-2025

Unlocking Plastics Industry Potential at K-2025

At this year’s K-Show in Duesseldorf, the MAAG Group will unveil a host of innovative technologies for the plastics industry from October 8-15, 2025 in hall 9, booth A02, all centered around integrated system solutions in pelletizing, extrusion, filtration, recycling as well as measurement and controls. Visitors can expect a wide range of new products and technological developments.

“Our systems stand for innovation, quality, and efficiency. At K-2025, we will show how technical excellence and smart design are transforming the future of plastics processing.” Says Ueli Thuerig, President of MAAG Group.

New NG-USG Strandpelletizer

Debut of the PEARLO CS – Compact Excellence in Underwater Pelletizing

The new PEARLO CS marks a milestone in compact pelletizing systems. Drawing on the proven PEARLO series, it features the familiar tangential cutting chamber and optimized cutter design. Offered in two sizes, it targets production scales where flexibility and efficiency are essential. “We developed the PEARLO CS specifically for manufacturers who need top-tier performance in a streamlined footprint,” explains Product Manager Rico Sandmann.

NG-USG Redefined – Enhanced Design for Maximum Throughput With an enlarged rotor diameter and improved water flow, the next generation NG-USG underwater strand pelletizing system enables greater throughput and superior pellet quality. Additional sensors boost process stability. These design enhancements help to achieve consistent quality with increased performance.

Compact Pelletizing System PEARLO CS

EBG – Dust-Reducing Dry Cut Strand Pelletizing System

This semi-automated system offers flexible process control with reduced strand breaks, low moisture content, and minimized dust formation – a reliable solution for demanding applications.

Global Innovation: extrex⁶ EC – Gear Pump for Rigid PVC Processing

MAAG unveils a world first: the extrex⁶ EC gear pump, designed for conveying rigid PVC. It delivers unprecedented levels of process safety, product quality, and resource efficiency. “With the extrex⁶ EC, a new chapter in PVC extrusion technology is opened.” Says Jonathan Hummer, Head of Product Management Pumps.

BRF & ERF – Double-Stage Melt Filtration for Sustainable Recycling

MAAG introduces double-stage filtration for advanced polymer recycling. As the BRF coarse melt filter enhances downstream equipment protection and ensures stable operation, the ERF fine filter guarantees exceptional pellet quality with minimal material loss. These filters offer a powerful combination for efficient, low-cost recycling solutions.

CSC-R-DV – Streamlined Screen Changer for Increased Output

The new curved, continuous screen changer CSC-R-DV with integrated start-up position offers up to 50% higher throughput and energy savings, while significantly shortening the production line. Its compact design reduces investment costs and fits perfectly into temperature-sensitive extrusion processes.

Virgin Polymers in Focus: PEARLO 350 & CIS System

MAAG introduces the largest underwater pelletizing system for PET production with the PEARLO 350 pelletizer equipped with EAC technology and new die plate design, ensuring long tool life, precise cutting and reduced fines for premium granulate. For high throughputs, the Central Injection System (CIS) die plate introduces water centrally through the die plate to reduce agglomerates and improve pellet cooling for high-MI polymers.

New Centrifugal Dryer Lab in the US

MAAG has commissioned the new centrifugal dryer lab as a key part of the Centrifugal Dryer Center of Excellence in Eagle Rock, VA. The lab will enable MAAG to further optimize and innovate centrifugal dryers for virgin polymer, recycling, and compounding systems. Focus for the lab include improved energy efficiency, drying performance, noise reduction and to build application specific knowledge for future innovation. For customers, the Centrifugal Dryer Lab can be utilized for drying tests up to 72,000 kg/hr.

Welcome to the MAAG Group Family: Sikora GmbH

Since June 2025, Sikora GmbH has joined the MAAG Group. Sikora will present their innovative measurement, control, inspection, and sorting technologies for quality control in the plastics industry at K-Show in Hall 10, Booth F14.

https://maag.com/

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Smart assistant ensures maximum flexibility and efficiency in event planning

Anthony George
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Smart assistant ensures maximum flexibility and efficiency in event planning

Smart assistant ensures maximum flexibility and efficiency in event planning

K in Düsseldorf now offers the AI-supported chatbot ‘K Assistant’, a virtual companion that provides exhibitors and visitors with targeted information around the clock – individually, multilingually and intelligently.

K Assistant is available to assist anyone interested at www.k-online.com. Whether you need initial information on hall plans, exhibitor offers, the supporting programmed or services, the chatbot ensures you are perfectly prepared for an optimal trade fair experience.

‘With K Assistant, we are offering an innovative service that enables visitors and exhibitors to plan their trade fair visit even more efficiently,’ explains Thomas Franken, Director K at Messe Düsseldorf. ‘Digital tools such as the chatbot are an important step towards offering our customers modern and user-friendly support.’

More than just a chat – what the K Assistant can do:

  • Available 24/7: The AI chatbot is available to users at any time of the day or night, ensuring maximum planning freedom.
  • Intelligent answers instead of mere search results: The ‘K Assistant’ thinks for itself – it analyses questions in context and provides structured, precise information instead of long lists of hits.
  • Language diversity for global target groups: Visitors and exhibitors from all over the world benefit from the multilingualism of the system, which communicates in numerous national languages.

The friendly symbol for the K Assistant can always be found at the bottom right-hand corner of www.k-online.com.

www.k-online.com

#K2025 #Modernplasticsindia #Pasticsnews #ModernPlasticsIndiaMagazine
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Industry Leaders Eye Growth After Major Investment

Nora Szabó
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Industry Leaders Eye Growth After Major Investment

Industry Leaders Eye Growth After Major Investment

Constantia Flexibles kicked off 2025 with key milestones: acquiring Aluflexpack, expanding its product portfolio, and launching digital printing in Denmark. Its Low Carbon Aluminum Product Carbon Footprint (PCF) calculation has been validated by TÜV Süd. Visit booth 4-523 to explore the company’s innovations.

Constantia Flexibles, the world’s third-largest producer of flexible packaging, enters FACHPACK 2025 following a period of strategic investment, technological advancement, and portfolio expansion, reinforcing its position in premium flexible packaging and sustainability leadership.

Earlier this year, Constantia Flexibles completed the acquisition of Aluflexpack, a leading European supplier of customized flexible packaging solutions. This move significantly strengthens Constantia Flexibles’ footprint in high-value segments, particularly in the food and pharmaceutical industries, while enhancing its technological capabilities and regional production reach.

“We have entered 2025 with a clear focus on delivering flexible packaging ready for tomorrow’s challenges,” said Marc Rademacher, Executive Vice President Consumer Commercial at Constantia Flexibles. “The acquisition of Aluflexpack and our investments across our production plants are not just about growth—they are about creating an agile, future-ready packaging network that serves our customers with greater speed, technical depth, and environmental responsibility.”

With this new addition to the Group, Constantia Flexibles is proud to showcase an expanded product portfolio at FACHPACK 2025 in Nuremberg, September 23-25 at booth 4-523, where it will present a range of innovations, including its Ecolutions portfolio, advanced pouch solutions, and new lidding materials. Constantia Flexibles and Syntegon will jointly present pouches produced on Syntegon’s PMX line to showcase the advanced real-world performance of Constantia Flexibles’ mono-materials EcoLamHighPlus (mono-polyethylene) and EcoVerHighPlus (mono-polypropylene)—for these packaging formats. Constantia Flexibles will also show EcoVerHighPlus in a collaboration with machine builder Wolf Verpackungsmaschinen, featuring a live demonstration at booth 1-428.

Over 100 million invested in global facilities

Constantia Flexibles has committed over 100 million to upgrading its global production network. In Austria, 50 million has been invested in expanding the rolling mill at the Constantia Teich plant, increasing aluminum foil production by around 30 percent up to 90,000 tons annually. An additional 30 million has been allocated to a new lacquering line. In Germany, Constantia Flexibles has invested more than 6 million in a new machine-direct orientation (MDO) line at its Constantia Pirk facility. This advanced line supports the production of EcoLamHighPlus. In Spain, the Burgos plant of Constantia Tobepal has been enhanced with over 15 million for a tandem extruder, increasing capacity and providing a reliable backup for the Logroño site. Meanwhile, in Mexico, the company has invested significantly into the Constantia Aluprint plant to improve speed, reliability, and efficiency.

Digital Printing: Ready to meet the demands of customization and speed

A major technology milestone has been reached with the installation of a state-of-the-art digital printing line at the company’s site in Copenhagen. This industry-first solution allows water-based, full-surface digital printing on aluminum and PET substrates. The system eliminates the need for clichés or plates, enabling rapid design-to-print turnaround while covering 93 percent of Pantone colors. It also allows mass customization while reducing waste.

Low Carbon Aluminum: Product Carbon Footprint calculation methodology validated by TÜV Süd

Further reinforcing its environmental commitment, Constantia Flexibles has received third-party validation from TÜV SÜD for its Product Carbon Footprint (PCF) calculation methodology for Low Carbon Aluminum. It ensures the accuracy and transparency of carbon footprint data across the value chain, empowering customers to make informed, measurable progress towards their own sustainability targets.

HIGHLIGHT PRODUCTS AT FACHPACK 2025

Live at FACHPACK: Ecolutions range for a circular economy

At FACHPACK 2025, the company will spotlight its Ecolutions range, which offers a comprehensive selection of mono-material packaging Designed for Recycling. The portfolio includes EcoLam, a family of PE-based laminates designed for the PE recycling stream, available in multiple barrier levels including EcoLamHighPlus, which rivals traditional PET/Alu/PE structures. EcoVer, based on mono-PP, delivers excellent clarity, heat resistance, and sealing performance, making it ideal for a wide range of applications. Complementing these is EcoAlu, featuring lightweight aluminum-based solutions like AluTainerRetort, which provides high barrier protection for demanding uses such as retortable food packaging.

LEADING THE LIDDING BUSINESS

ComforLid: The new standard for aluminum die-cut lids

Constantia Flexibles is redefining convenience and sustainability with ComforLid – an innovative aluminum lid that combines hygiene, recyclability, and reduced CO₂ emissions. Designed with consumer convenience in mind, ComforLid replaces traditional plastic lids while maintaining ease of use and improving environmental impact. Its optimized material composition ensures full recyclability via existing systems, while upcoming production with Low Carbon Aluminum will cut greenhouse gas emissions by up to 43 percent. With integrated drinking functionality and broad application potential, ComforLid sets a new standard for future-ready packaging.

EcoPeelCover: The thinnest aluminum lid in the Ecolutions family

In addition to ComforLid, Constantia Flexibles has developed another aluminum lid focused on resource conservation: EcoPeelCover, the world’s thinnest die-cut aluminum lid of its kind. It significantly reduces material usage—by 25 percent in aluminum thickness and 50 percent in coating weight. Printing is done solvent-free using the UV flexographic printing process.

Despite its ultra-thin structure, the lid meets high-performance standards: it is puncture-resistant, provides reliable protection against oxygen and moisture, and withstands sealing temperatures of up to 230°C. As part of the Ecolutions product family, it is also available in Low Carbon Aluminum variants and with ASI certification.

This specification has been recognized with top industry honors, winning the prestigious German Packaging Award in 2024 and the Global Packaging Award in 2025.

CONSTANTIA FLEXIBLES EXPANDS POUCH PORTFOLIO

Smart design meets real-world functionality: The versatile pouch portfolio

Following the integrationwith Aluflexpack, Constantia Flexibles is elevating its pouch portfolio—offering smart, high-performance packaging for food, pet food, dairy, confectionery, and pharma. Thanks to a fully integrated production process, including film manufacturing and pouch forming with features like zippers or spouts, customers benefit from faster lead times, tailored solutions, and consistent quality. Available in various shapes, sizes, and materials, these pouches also feature advanced printing and customizable options, making them ideal for diverse market needs.

EcoVer Spouted Pouch – premade pouch with and without spout: A PP-based packaging innovation

A recent highlight is the launch of the mono PP spouted pouch—a fully aluminum-free solution that is Designed for Recycling in the respective recycling stream. This innovative pouch offers exceptional oxygen and water vapor barrier properties, making it ideal for shelf-stable products that undergo hot-filling and pasteurization, such as baby food, fruit purée, and wet pet food, as well as for cold-filled or dairy applications. The spouted pouch is available in three different barrier grades: EcoVer, EcoVerPlus, and EcoVerHighPlus.

EcoVer Retort Pouch: PP-based mono-material retort pouch for wet pet food and ready-made meals

A major innovation in pouch packaging is the new retortable mono PP pouch, engineered for high-heat applications like wet pet food and ready meals. This high barrier solution withstands retort processing while aligning with European PP recycling streams. EcoVer Retort Pouch offers high oxygen and moisture barriers, ensuring product safety and shelf life, and provides a Designed for Recycling alternative to traditional multi-material laminates.

HIGH-PERFORMANCE ALUMINUM SOLUTIONS FOR WET, DRY, AND RETORT APPLICATIONS

Alufoil Container: A smart choice for wet and preserved food applications

In addition to its pouch solutions, Constantia Flexibles offers high-performance Alufoil Containers, ideal for applications such as meat, fish, ready meals, desserts, and pet care. Engineered to meet the highest performance and quality standards, these containers leverage the functional benefits of aluminum, including direct food contact suitability at high temperatures and exceptional barrier protection at minimal thickness. With fully customizable material specifications, creative shaping options for brand differentiation, and full-surface printability, the Alufoil Container delivers both technical excellence and strong shelf appeal.

Foil for peel-off end: For retort and dry applications

Also new in the portfolio of Constantia Flexibles is a premium peel-off foil solution from Aluflexpack, designed to deliver high-performance barrier protection alongside effortless consumer convenience. Suitable for both retort and dry applications, the foil withstands high temperatures and pressure during sterilization, making it ideal for food, pet food, pharmaceuticals, dairy powders, snacks, and supplements. It ensures long-lasting freshness and a clean, easy-open experience. Fully customizable, it adapts to diverse packaging needs across industries

www.cflex.com

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Modular Coating That Lasts Longer and Wastes Less

Anagha Salvi
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0
Modular Coating That Lasts Longer and Wastes Less

Modular Coating That Lasts Longer and Wastes Less

Modular upgrades for line transformation and production increase

Targeted retrofit solutions for tomorrow’s state-of-the-art BO film stretching lines:

  • Inline coating upgrade (ILC): With layer thicknesses in the nanometer range, new formulas improve printability and take the barrier properties of BOPP films to a new level. In recent years, Brückner Maschinenbau and Servtec have sold more than 25 ILC systems that support the production of recyclable mono-material packaging – as required by EU Regulation 2025/40 on packaging and packaging waste (PPWR).
  • BOPE upgrade: The enhanced concept supplements existing BOPP lines with the option of producing LLD-PE and HD-PE – an important element for mono-material solutions for simplified recycling. It is an integral part of the portfolio and enables nearly 100% PE output compared to the original production, for example by means of targeted extruder modifications.
  • Productivity upgrade: An efficient solution to increase the line output – using mechanical, electrical, or software-based measures, depending on requirements. Here is one example: Optimization of the highly complex TDO (transversal direction orienter) chain system component, for instance by replacing FOK 4.4.6 with FOK 8.8. In combination with double nips in the MDO (machine direction orienter) stretching frame, additional TDO frequency converters, or updating the IMC software, production speed can be increased by up to 20%.

New performance services 

Fast on-site support for film manufacturers thanks to new service products.

  • Line inspection (1 day): Analysis of the line processes to reveal hidden efficiency potential – including immediately implementable optimization measures such as process parameter adjustments
  • KPI check (3 days): Industry comparison based on real operating data to assess key performance indicators (energy consumption, maintenance quality, productivity) and derived conversion and service suggestions
  • Performance boost (5 days): Profound process optimization with a focus on increased production output, improved energy efficiency, and knowledge transfer. In addition: targeted approaches to quality improvements and the development of future-oriented film types. In comparable applications, the line yield was increased by up to 40%.

Brückner ONE: the next step in digital services

The current generation of Brückner ONE provides advancements for increased efficiency, safety, and flexibility in digital line operation.

  • Condition monitoring 2.0: Shorter reporting intervals, in-depth analyses, and specific recommendations for action allow for an even more targeted condition monitoring of key line components (main extruder gearbox, TDO chain, parts of the extraction system) as well as early planning of maintenance measures. Further line components will be integrated successively.
  • Support: For the first time converted to web technology and decoupled from the line network, it combines a ticket system with remote support and a communication solution. A central overview of all lines and flexible access independent of locations and devices increase the user friendliness and deepen the internal know-how.
  • Cybersecurity service: The level of security is strengthened further and expanded in accordance with legal requirements. Continuous monitoring detects dynamic security gaps and digital cyber threats at an early stage, allowing for specific response measures to be initiated by the customer to secure their production environment.

Brückner Academy: state-of-the-art training with a digital line twin

Sustainable training courses for improved operating skills.

  • Central platform for all existing and new programs
  • Expanded portfolio: operator training (essential & advanced), electrical/mechanical maintenance (essential & advanced), and customized training
  • Training on the digital line twin: simulations of line operation, optimization, and realistic emergency & malfunction scenarios; without affecting the ongoing film production
  • Flexible implementation by experts: hands-on at the customer’s site, in Brückner training centers worldwide, or in Siegsdorf

Future. Made by Brückner Group

As part of a world-leading group of companies, Brückner Servtec builds on a strong foundation of shared expertise and innovation. United by a common vision, the Brückner Group aims to shape global markets and the future of plastic and material processing with sustainable solutions – flexible, fast and customer-focused. To make this shared purpose tangible, the Group and its business units will be represented together at a joint stand for the first time. This presence offers customers and stakeholders the opportunity to experience the combined strength of leading global companies in the fields of plastics and alternatives, packaging and technical applications, machinery and production plants, as well as holistic solution providing.

Each business unit contributes cutting-edge technologies for future-oriented markets that embody the Brückner Group’s collective commitment to sustainability, digitalization, and technological leadership. From more efficient production technologies and smart automation to new packaging approaches and digital interfaces – these developments reflect the shared drive to lead with purpose.

Together, they stand for collaboration, excellence, and a bold vision: shaping the industry of today and tomorrow.

https://www.brueckner.com/en

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