Key Takeaways
- The plastics processing industry is constantly evolving with new technologies and innovations emerging every month.
- Researchers are working on scaling up biomanufacturing processes for succinic acid, a key building block for industrial chemicals and biopolymers.
- Companies are adopting new technologies such as blow molding, EVO Fusion, and MixFlow extruders to improve productivity and reduce waste.
- Sustainability is a major focus, with companies utilizing recycled materials, reducing waste, and developing bio-based alternatives to fossil-based materials.
- New technologies are being developed to improve measurement, processing, and recycling of plastics, including in-line measurement systems and solvent wash processes.
Introduction to Plastics Processing Technologies
The plastics processing industry is constantly evolving, with new technologies and innovations emerging every month. In 2025, PT’s editors used the monthly Close Up column to report on the latest developments in plastics processing technologies. These cutting-edge technologies, often originating in labs and R&D centers, are headed to a shop floor near you. From biomanufacturing processes to new molding techniques, these innovations are set to transform the industry. For instance, researchers are working on scaling up biomanufacturing processes for succinic acid, a key building block for industrial chemicals and biopolymers. This technology has the potential to revolutionize the production of biodegradable plastics and other sustainable materials.
New Technologies and Innovations
In the first few months of 2025, several new technologies and innovations were reported. In January, a leading maker of portable sanitation products discovered the benefits of blow molding, which allowed them to increase productivity and enter new markets. The SPE Automotive event also recognized several "firsts" in the industry, including sustainable technologies and materials. In February, it was reported that proper quality controls and feedstream selection can produce recycled materials for any application, highlighting the importance of quality control in the recycling process. Additionally, the Plastics Technology Expo (PTXPO) provided attendees with the opportunity to gather information on the latest technologies and bring back knowledge to their organizations. The expo featured exhibits on various topics, including bioplastics, recycling, and sustainable packaging.
Sustainability and Recycling
Sustainability is a major focus in the plastics processing industry, with many companies adopting new technologies and practices to reduce waste and improve recycling. In March, it was reported that MixFlow extruders rely on conductive heating to melt plastics, which can help reduce energy consumption and improve efficiency. Additionally, companies such as CarbonFree are converting steel slag and blast furnace exhaust into important plastic compounding additives, reducing waste and creating new materials. In April, a patented technology was described that uses a specialized tool, a standard injection molding machine, and off-the-shelf components to replace compression molding and extrusion for large stock shapes. This technology has the potential to reduce waste and improve efficiency in the production of large plastic parts.
Company Developments and Partnerships
Throughout the year, several companies made significant developments and partnerships in the plastics processing industry. In May, Amorim Cork Solutions enabled bio-based designs for injection-molded products, highlighting the growing trend towards sustainable materials. In June, Currier Plastics’ continuous improvement program brought new efficiencies in processing, packaging, and shipping for the molder and its customers. Valerian Materials was also founded to commercialize the results of federally funded research conducted at the University of Minnesota, producing bio-based alternatives to fossil-based polyurethanes. These developments demonstrate the industry’s commitment to sustainability and innovation.
New Technologies and Processes
In the second half of the year, several new technologies and processes were reported. In July, a retrofittable system was developed that adds turbulent cooling to calibrators, boosting output by 25-50%. In August, the disc golf company Trash Panda developed discs from recycled materials, highlighting the potential for sustainable products in various industries. In October, John Winzeler looked back on his 58 years in the family injection molding business and how he found a compatible home for it within a larger molding firm. Additionally, waste analytics technology was reported to be taking the guessing out of recycling, improving the efficiency and effectiveness of recycling processes.
Future Developments and Trends
As the year came to a close, several future developments and trends were reported. In November, Oboro Labs aimed to scale production of cyclic polymers, which have the potential to improve the sustainability and performance of various plastic products. CAE Services also developed a hybrid simulation/real-world methodology to ensure better outcomes for designs prone to warpage. In December, Incroflo used biobased feedstocks and improved extrusion outcomes, highlighting the growing trend towards sustainable materials and processes. New controls technology was also reported to minimize operator involvement and required expertise, while MDO technology continued to advance. These developments demonstrate the industry’s commitment to innovation and sustainability, and highlight the potential for future growth and improvement.
Conclusion
In conclusion, the plastics processing industry is constantly evolving, with new technologies and innovations emerging every month. From biomanufacturing processes to new molding techniques, these innovations are set to transform the industry. Sustainability is a major focus, with companies adopting new technologies and practices to reduce waste and improve recycling. As the industry continues to grow and develop, it is likely that we will see even more exciting innovations and advancements in the years to come. With the industry’s commitment to sustainability and innovation, the future of plastics processing looks bright. The potential for growth and improvement is vast, and it will be exciting to see how the industry develops in the coming years.