Opinion: K defies all challenges to remain the centre of the plastics world

Large areas of the global economy are currently experiencing economic headwinds. So, what sort of signal does an already fully booked K 2025 send?

Ulrich Reifenhaeuser: It shows that the global assessment of the industry remains positive. In the past, the plastics industry has developed outstanding products and valuable solutions, and this will continue in the future. Plastic is a relatively young material, which still has enormous potential. Yes, we are going through difficult economic times, but they will pass. In principle, this does not change the need for plastic solutions. We want to display and see them. That's why the K defies all challenges and remains the centre of the plastics world.

Thorsten Kuehmann: We are going through a time of great uncertainty. However, there are some fixed stars of considerable radiant power, of which the K is one such star. Everyone knows that the K is taking place, and the world is heading there. It provides the orientation that is especially needed in difficult times. This is also reflected in the motto of K 2025: "The Power of Plastics - Green, Smart, Responsible”.

That motto exudes great self-confidence. What is it based on?

Kuehmann: We believe that plastic as a material offers the solution to the major issues facing our civilisation. For example, plastic helps to improve the global climate.

This is because CO2 emissions are decreasing as vehicles are becoming lighter due to the higher use of plastic, thereby consuming less energy. Energy consumption is also greatly reduced in the construction industry because buildings are better insulated with plastic. The CO2 footprint is reduced because plastic packaging means less food spoilage. These are all major contributions from the plastics industry. Another point is the circular economy: resources are not only used once, but again and again. We are creating recyclability. A great deal is already possible, hence the motto "The Power of Plastics". We just need to do it.

Reifenhaeuser: It is a fact that we have a huge climate problem in this world. It is also true that plastic is the most climate-friendly material. Its production consumes significantly less CO2 than that of other materials. This climate advantage would be immediately visible if, for example, the CO2 footprint was labelled on packaging. It is therefore not presumptuous to be very self-confident.

The circular economy is still in its early stages. Where do we stand today?

Reifenhaeuser: We are further than we were three years ago. Mechanical engineering has now reached an astonishingly high level. The technical solutions for recycling are largely available. However, we could actually be three times better off than we actually are; in other words, we could recycle much more. Why aren't we doing that? Because recycling is technically demanding, and therefore more expensive than virgin plastic. No-one is prepared to pay the higher costs. Consumers are extremely cost-conscious, plus brand manufacturers are under enormous competitive pressure. Plastic has been a success because it is far better than other materials. However, the step towards a circular economy is costly. It will not be possible to get to grips with this cost problem without regulatory requirements.

Kuehmann: That's true, but there is light on the horizon. One key to reducing costs would be a vastly increased penetration of digitalisation. On the one hand, this concerns the digitalisation of machine and plant systems, allowing processes to be better controlled. It also makes it easier to handle difficult materials – and recyclates are more difficult to handle. On the other hand, material flows also need to be digitalised. This is where the digital product passport comes in for example, which digitally tracks a product over its entire life cycle. Machines and products are two levers that can be used to bring costs down. It will still take time, but we are well on the way.

How far have companies actually progressed with digitalisation? Is AI already being utilised?

Kuehmann: Virtually every company in the plastics machinery industry is now focusing on digitalisation. This topic is now current all across the globe, with many companies even already focusing on digital sales. Recently, artificial intelligence has also been finding its way into the industry. In the process of digitalising their operations, companies have so much data available, that they can simply solve certain requirements much better with intelligent algorithms. Three years ago, nobody was talking about artificial intelligence, now it’s on everyone’s lips - and there are also the first practical examples.

Reifenhaeuser: Automation has been used in plastics machinery manufacturing for over 40 years. Now almost everyone is going one step further and focusing on digitalisation. In essence, this means that much larger amounts of data and therefore more information are being registered due to faster processors. This allows processes to be noticeably improved once again. The next step is the intelligent processing of the different types of information. This brings us to AI, which generates enormous added value – in design, production and service. The potential is enormous. 

Where do employees stand in the future of plastics engineering?

Kuehmann: Our employees are one of the most important assets we have - all the more so because demographic trends show the difficulty in recruiting enough young people with certain qualifications. On the one hand, we must therefore try to make mechanical engineering attractive to more people, especially women. On the other hand, we need to push ahead with digitalisation, including AI. This will streamline processes and ultimately allow us to manage with fewer but qualified staff.

How will the VDMA address these specific issues at K?

Kuehmann: At the trade fair, we will bring to life the motto we have developed together with our members and partners: "The Power of Plastics - Green, Smart, Responsible". We will make all facets of this motto visible to visitors. In the outdoor area of K, companies will present concrete solutions and thereby show where we currently stand as an industry: in recycling, in plastics processing, and in digitalisation. To this end, we will be providing an overview of all these machine applications and digitalisation solutions in the VDMA Dome. There, we will also be discussing topics relating to talented young prospects.

Reifenhaeuser: This exhibition in the outdoor area will of course be flanked by the innovations and special developments that will be on show at the individual companies' stands. So, you can experience both: the strength of plastics as a whole on the VDMA site, and the technical finesse at the company stands. There will once again be plenty to see. In plastics machinery manufacturing, the development cycles in the companies are closely aligned with the three-year cycle of the K trade fair. This also explains why suppliers are always so keen to present their products, and why the trade visitors remain so interested.