"We have never had such efficient systems as we have today"

April, 15, 2025 – Mr. Perrevort, the next K’s motto: "The Power of Plastics" is an expression of the sector’s self-confidence. Is this justifiably so in your view?

Definitely, because we can see that the image of plastic has changed significantly. Today, plastic is no longer seen as a problem, but as a valuable material that can make a significant contribution towards solving many of the world's problems - only if it is used in the proper manner, of course. The discussion about plastic has become much more objective and realistic, both among our customers and our employees. Most companies in our industry today want to contribute towards using plastics responsibly. At the same time, operations must be cost-effective. At K, we will be demonstrating that a combination of both is possible.

The second part of the motto is: "Green - Smart - Responsible". Where is Reifenhäuser’s focus in this respect?

We have been active in all three fields for some time now. We are pushing downgauging, meaning the production of ever thinner films with equal – or even better – properties. This allows us to save a considerable amount of CO2 with a material that often has a better carbon footprint than other packaging materials anyway. The topic of "smart", i.e. digitalisation and automation, is also pushing the CO2 balance: we have never had such efficient systems as we have today, which manufacture high-performance products with minimal raw material consumption, optimised energy use and minimised waste. There have already been quite a few developments, and these are ongoing constantly. However, smart systems are above all a response to the shortage of skilled labour. Assistance systems and automation features help film manufacturers to ensure their productivity and quality – even if perfectly trained staff are not available. And of course, automation also makes systems safer, which brings us to the topic of ‘responsibility’. For us, this includes responsibility towards the environment, towards our own employees and towards our customers' employees. The topics Green - Smart - Responsible are extremely diverse and, in our view, closely linked.

Which specific projects are you pursuing in this respect?

There are quite a few: in terms of ‘Smart’, we have set up special units for digitalisation and education: RE: GmbH, R-Cycle and our AR:DEL Academy. We have invested heavily in this area and created market-ready solutions that offer our customers added value, not solely for Reifenhäuser machines, but even beyond that. For example, all machines along the value chain can be networked: in addition to an extrusion machine for example, you can connect a printing machine, recycling line and more besides. The aim is to produce more efficiently and sustainably through digitalisation. There is still considerable potential in this area in particular within the plastics industry.

To what extent is the struggling economy in large parts of the world slowing down the development of your industry?

There are obstacles all across the board. One of these is the overcapacity that has accumulated during the pandemic in particular. This is most prevalent in the hygiene sector, but is also noticeable elsewhere. Investments are still being made in machinery and equipment, but the brakes are definitely on. Many companies are also concerned about geopolitics and the threat of trade barriers, and there are considerable uncertainties. Nevertheless, we are observing the first signs of a slow recovery in the markets. In the meantime, we are continuing to invest in the key future areas, and related added value for our customers.

What can be done to manage this widespread reluctance to invest?

We support customers in becoming more efficient with their existing equipment. Manufacturers are currently less likely to invest in large new systems with an additional capacity of 1000 kg per hour, but are definitely interested in improving the end quality of the product or making production more efficient. We therefore show what can be achieved with retrofits or special solutions in the field of digitalisation. The solutions yield a quick return on investment and are therefore well received. Customer margins are severely under pressure.

Is this pressure at the expense of sustainability?

I wouldn't say that. Firstly, awareness of sustainability is already firmly anchored in our industry. Secondly, we can see that there is no turning back on this path. The transition from a linear to a circular economy is being driven forward politically, for example by the new European packaging regulation PPWR, which is now gradually coming into force. This is a particular concern for major brand owners, as many questions remain unanswered in this context, such as where recyclates in sufficient quantity and quality to fulfil the 30 percent recyclate content directive can be sourced – depending on the type of packaging, and how the prescribed recyclate content can be realised for food packaging, where that use of recyclates is often still prohibited by other regulations. All market players are dealing with these questions and working on solutions to be ready for when the enforced turnaround comes. We are convinced that this pressure is necessary. Today, recyclable solutions are often more expensive and would not establish themselves on the market so quickly without regulatory intervention.

What developments do you expect to see in the future?

I believe we will see a leap in automation at the next K – in film extrusion, but in other areas of plastics processing as well. There will also be another significant leap in efficiency, particularly in those technologies that contribute towards the circular economy. For example, we were able to produce recyclable all-PE mono-material film with a thickness of just 18 micrometres, which means that it can compete economically with conventional PET-PE film for the first time. At the last K, the topic of digitalisation was still relatively abstract. This year we will see many more implementable applications. The trend towards modularity will continue. Customers will decide for themselves how they wish to equip their machines, and to what extent digitalisation will assist them – including AI applications, where the actual benefits can already be seen today, and where enormous potential for improvement is opening up.

Source: VDMA