---
title: "Plastics 2028: AI, Circularity, and Smart Materials from K-2025"
id: "10290"
type: "post"
slug: "plastics-2028-ai-circularity-and-smart-materials-from-k-2025"
published_at: "2025-12-13T17:54:34+00:00"
modified_at: "2025-12-12T14:13:49+00:00"
url: "https://www.plasticsengineering.org/2025/12/plastics-2028-ai-circularity-and-smart-materials-from-k-2025-010290/"
markdown_url: "https://www.plasticsengineering.org/2025/12/plastics-2028-ai-circularity-and-smart-materials-from-k-2025-010290.md"
excerpt: "The future of plastics engineering is evolving rapidly, and K-Show 2025 in Düsseldorf showcased groundbreaking innovations that will shape the next three years."
taxonomy_category:
  - "Circular Economy"
  - "Design"
  - "Industry"
  - "Materials"
  - "Resins"
  - "Sustainability"
  - "Trending"
taxonomy_post_tag:
  - "AI in manufacturing"
  - "AI-driven injection molding"
  - "BASF recycling strategy"
  - "Chemical Recycling"
  - "Circular Economy"
  - "Covestro mono-material"
  - "digitalization in plastics"
  - "Engel Inject AI"
  - "Erema Blueport"
  - "future of plastics engineering"
  - "Haitian turnkey solutions"
  - "Industry 4.0 plastics"
  - "injection molding technology"
  - "K Show 2025"
  - "Mechanical Recycling"
  - "Plastics industry"
  - "plastics recycling trends"
  - "polyurethane recycling"
  - "predictive maintenance"
  - "smart materials"
  - "Sustainable Plastics"
  - "Wacker silicon solutions"
---

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# Plastics 2028: AI, Circularity, and Smart Materials from K-2025

 Press Conference from ENGEL at the K-Show 2025. Photo by Andrés Urbina.### **The future of plastics engineering is evolving rapidly, and K-Show 2025 in Düsseldorf showcased groundbreaking innovations that will shape the next three years.**

From AI-driven injection molding to circular economy strategies, and from smart materials to digitalization, industry leaders revealed what’s coming and how the future of plastics will be.

**You can also read:**[Next Gen Injection Molding: Best Practices](https://www.plasticsengineering.org/2024/08/injection-molding-best-practices-005823/)

This article is a sample of interviews conducted by Plastics Engineering with selected exhibitors, offering a clear forecast from top players in materials to machinery. If you want to stay ahead in the plastics industry, keep reading because these insights will define the future.

## **Interviewed Experts**

- **Gerhard Dunkler**, CTO – **Engel Austria**
- **Felix Schmidt**, Application Engineering Manager – **Engel Mexico**
- **Dominik Wiesner**, Marketing Manager Europe – **Haitian International**
- **Markus Huber-Lindinger**, Managing Director – **EREMA Group**
- **Roel Gunnink**, Director of Marketing Insulating Solutions – Performance Materials EMEA – **BASF**
- **Christian Arger**, Marketing Manager – **Wacker Chemie AG**
- **Covestro Circularity & Recycling Division Team**

## **Injection Molding Technology – From Inject 4.0 to Inject AI**

Engel is pushing boundaries with Inject AI, which represents a significant leap forward from the connectivity-driven Inject 4.0 introduced in 2016. In the photo are from left to right: Felix Schmidt (Application Engineering Manager – Engel Mexico), Andres Urbina (Content Editor Europe – Plastics Engineering powered by SPE) and Christian Öllinger (Global Key Account Manager Automotive – Engel Austria). Photo by Andrés Urbina at the K-Show 2025.

First of all, Engel is pushing boundaries with Inject AI, which represents a significant leap forward from the connectivity-driven Inject 4.0 introduced in 2016. As a result, Engel now focuses on true machine intelligence rather than simple data transparency. Furthermore, this shift enables manufacturers to achieve unprecedented levels of automation and efficiency.

### **Key Highlights**

- **Autonomous Injection Molding**: Machines detect out-of-spec parts and recalibrate automatically after the first two shots. Consequently, scrap and downtime are minimized, ensuring consistent quality.
- **Validation Assistant**: This intelligent system reduces validation time by up to 30% through automated data capture from machines, molds, and processes.
- **Victory Series Upgrade**: By combining tie-bar-less design with electric drives, Engel delivers precision and energy efficiency in one package.
- **Physical Foaming Competence**: After acquiring Trexel, Engel now offers advanced foaming solutions for lightweight components.
- **EVA (Engel Virtual Assistance)**: A digital assistant that supports operators during development and production phases.

**Forecast:**By 2028, 40% of new injection molding machines will feature AI-driven autonomy, while all-electric machines will grow at 8–10% CAGR.

## **Smart Materials and PU Integration**

Engel and Cannon’s Cleaner Competence Center (CCC) introduces hybrid PU + thermoplastic solutions for large parts (up to **5500 tons**), cutting emissions and improving recyclability.

## **Haitian – Scale and Turnkey Solutions**

Similarly, Haitian positions itself as a global powerhouse with a strategy centered on turnkey solutions. Therefore, customers receive not only machines but also complete ecosystems that include automation and software integration.

### **Key Technologies**

- **Integrated Automation**: Haitian delivers complete systems, including robots, peripherals, and process monitoring software.
- **Energy Efficiency**: Their all-electric and hybrid machines reduce energy consumption significantly.
- **Green Technology**: Haitian ensures compatibility with recycled materials, supporting sustainability goals.
- **HD Vision and AI**: Advanced vision systems and AI algorithms optimize cycle times and part quality.

**Why It Matters:**  
 Haitian’s ability to produce tens of thousands of machines annually ensures scalability for global markets.

## **Recycling – Erema’s Circular Vision**

Markus Huber-Lindinger (Managing Director – EREMA Group) highlights EREMA’s dual approach: mechanical and chemical recycling, supported by digitalization. Photo by Andrés Urbina at the K-Show 2025

In addition, Markus Huber-Lindinger highlights EREMA’s dual approach: mechanical and chemical recycling, supported by digitalization.

### **Breakthrough Technologies**

- **Eco Gentle System**: Processes up to 6 tons/hour of PP and PE without machine adjustments, improving efficiency.
- **Advanced Filtration**: Laser filters with double screen surface guarantee high melt purity.
- **Blueport Digital Platform**: Offers predictive maintenance, polymer behavior analysis, and operator training tools.
- **Sweet Spot Autotune**: Automatically finds optimal operating parameters, reducing operator dependency.

**Impact:**  
 Recycling capacity will grow 50% by 2028, with chemical recycling reaching 15–20% share. Predictive maintenance cuts downtime by up to 40%.

## **Covestro – Designing for Circularity**

Moreover, Covestro champions design for recyclability and chemical recycling innovations. As a result, they are leading the way toward a truly circular economy.

### **Technologies Driving Change**

- **Mono-Material Solutions**: Replaces multi-material composites with PU and TPU, simplifying recycling.
- **Advanced Simulation Software**: Simulates polyol foaming for dashboards and battery packs, reducing waste.
- **Chemical Recycling Methods**:
  - *Enzymatic Recycling*: Breaks down PU foams into polyols and amines.
  - *Smart Pyrolysis*: Recovers raw materials from rigid foams.
  - *Chemolysis*: Separates mattress components for reuse.

> *“We need to find solutions to come back to the building blocks.”*

## **Wacker – Digitalization Meets Sustainability**

Furthermore, Christian Arger emphasizes precision and sustainability, which are critical for future competitiveness.

### **Key Innovations**

- **Digital Twins**: Enable predictive modeling and process optimization.
- **SPC and AI Control**: Ensure consistent quality in high-volume production.
- **Sustainability Goals**: 50% emission reduction by 2030 and net zero by 2040.
- **Silicon Strip Technology**: Achieves 16-micron movement accuracy, critical for electronics and automotive applications.

## **BASF – Integrated Recycling Network**

BASF stresses collaboration across the value chain and supportive legislation to scale advanced recycling. Photo by Andrés Urbina at the K-Show 2025

Finally, Roel Gunnink introduces BASF’s tiered recycling system, matching waste complexity with the right technology. Consequently, BASF is creating a holistic approach to circularity.

- **Mechanical Recycling (“Back to Polymer”)**: For clean and homogeneous streams.
- **Chemical Recycling (“Back to Monomer”)**: Depolymerization for mixed or aged materials.
- **Feedstock Recycling (Pyrolysis & Gasification)**: Converts non-sortable waste into oil or syngas for chemical production.

**Core Philosophy:**  
 *“We use this waste as a valuable resource.”*

BASF stresses collaboration across the value chain and supportive legislation to scale advanced recycling.

### **What’s coming…**

In conclusion, the next three years will redefine plastics and injection molding through AI-driven autonomy, mono-material design, circular economy solutions, and integrated digital platforms. Companies that embrace digitalization and sustainability will lead the transformation.

**To read more:**[ENGEL at K 2025 – ENGEL](https://www.engelglobal.com/en/fairs-events/K2025)
, [Edvanced Recycling Inno­vations at K 2025](https://edvanced.erema.com/en/k2025/)
, [Covestro brings “The Material Effect” to K 2025](https://www.covestro.com/press/covestro-brings-the-material-effect-to-k-2025/)
, [WACKER at K 2025 – Empowering megatrends with silicones – Wacker Chemie AG](https://www.wacker.com/cms/en-us/products/insights/k-show.html)

By **[Andres Urbina](https://www.plasticsengineering.org/author/afurbina452/)** | December 13, 2025

[https://www.plasticsengineering.org](https://www.plasticsengineering.org)

##### [Andres Urbina](https://www.plasticsengineering.org/author/afurbina452/)

[Website](https://www.plasticsengineering.org)
 | [+ postsBio ⮌](#)

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