Trends and developments for the plastics industry in the future

Few topics are as polarizing right now as plastic. Plastic waste travels through the oceans worldwide, while tireless efforts are underway to find alternatives. The plastics industry is evolving, constantly seeking innovative recycling methods. Today, plastics are more eco-friendly and versatile than ever. Continuous changes in the industry can be observed, driven by new trends and developments.

To gain insight into the latest challenges and innovations, I attended the Fakuma trade fair for plastics processing in Friedrichshafen this year for the first time, alongside two colleagues. This blog post shares our experiences, the latest market trends and developments, and what exhibitors at the fair have to say about the future of plastics.

As a leading trade fair for plastics processing, Fakuma attracts thousands of industry professionals and exhibitors from around the world each year. This year, the event placed a clear focus on sustainable solutions and digitalization.

New Recycling Technologies

The circular economy was one of the leading topics at Fakuma 2024. This year’s fair was packed with innovative approaches and technologies aimed at making plastic recycling more efficient and economically attractive. One particularly promising trend at Fakuma was chemical recycling, where plastics are broken down at the molecular level into their basic components for reuse in new products. Several exhibitors showcased prototypes of recycling plants that use innovative catalysts to separate and recycle even complex plastic composites. These technologies could have a significant impact on increasing the proportion of recycled materials in production and, in the long term, provide an alternative to virgin plastic production.

However, despite recycling’s ongoing importance, there’s a general decline in interest, as it is often a financial matter, and currently, Germany shows limited investment enthusiasm, according to one exhibitor. Nonetheless, it remains a key topic with more business to be made in the future. The European Commission has already spurred the industry’s shift toward a circular economy with its decision that by 2030, all plastic packaging on the EU market must be reusable or cost-effectively recyclable (https://environment.ec.europa.eu/strategy/plastics-strategy_en).

Digitalization and Industry 4.0: The Path to the "Smart Factory"

Digitalization played a central role at Fakuma 2024. The introduction of Industry 4.0 in plastics processing is opening up new ways to optimize production processes and reduce material consumption. The fair showcased a variety of solutions that highlight the networking of machines and processes.

AI also plays a key role in customer management and CRM, helping answer questions about how to best support the market, find customers, and provide individualized treatment. Additionally, AI has become indispensable in managing supply and demand.

Another focus at the fair was the development of the “Smart Factory,” where production processes are fully digitized and automated. Machines and sensors monitor production in real time, allowing quick responses to quality issues. Various exhibitors demonstrated how AI-supported systems help analyze machine performance and make production processes more efficient. Fakuma 2024 also showcased applications where machines can automatically detect and report potential failures early. This optimization of operational uptime and reduction in energy consumption marks a significant step towards sustainability.

New High-Performance Materials and Hybrid Composites

The fair also served as a stage for numerous innovative materials that are both high-performance and environmentally friendly. High-performance plastics and hybrid materials developed for demanding applications in the automotive, aerospace, and medical industries were among the highlights. Even everyday items, like beach toys made from specific materials, showcased the latest innovations. For example, we spoke with an exhibitor producing beach ball paddles from a blend of recycled and new material, making the paddles reusable. This is just one example of how new materials and composites are making products more sustainable and reusable.

Particularly impressive are composite materials that combine traditional plastics with glass or carbon fibers. These hybrid materials offer the advantages of high stability and low weight, making them ideal for the automotive industry, where minimal material usage with high strength is essential. These materials help reduce the weight and, consequently, the energy consumption of vehicles, contributing to better material efficiency.

Sustainable Product Design

Sustainable product design was also a central part of Fakuma 2024. Ideally, products are designed from the start to be durable, repairable, and easy to recycle. These design strategies are an essential step towards reducing material consumption in the plastics industry over the long term.

Additionally, several exhibitors introduced new software solutions that allow companies to monitor and optimize a product’s entire lifecycle. These systems record a product’s carbon footprint—from raw material extraction to manufacturing and disposal—and help make the entire production process more sustainable.

Innovations in Injection Molding

Another focus of Fakuma 2024 was new technologies in injection molding and extrusion, which are central processes in plastics processing. Several exhibitors presented machines that enable more precise and energy-efficient processing.

Micromolding technology, in particular, attracted great interest. This technology allows the production of tiny, high-precision components, especially valuable for the medical technology and electronics sectors. Exciting innovations were also showcased in extrusion, where new energy-efficient machines deliver higher performance with lower energy consumption. This reduces both production costs and ecological impact.

Conclusion

The Fakuma 2024 trade fair impressively demonstrated how the plastics industry is actively tackling today’s challenges. Even though sustainability may be facing some setbacks, it will continue to play a central role in the coming years. Through the development of new recycling methods, the use of bioplastics, or the transformation to the Smart Factory, the fair provided a platform for forward-thinking technologies and solutions that aim to make the industry more sustainable and efficient in the long run. Current innovations show that plastic is far more than just packaging—it’s a material and a sustainable problem-solver. The coming years will be decisive in advancing this transformation and fully realizing plastic’s potential in a responsible, environmentally friendly direction.

Source:
Plastics strategy. (n.d.). Environment. https://environment.ec.europa.eu/strategy/plastics-strategy_en