Iranpolymer/Baspar The K 2025 International Exhibition, held from October 16 to 23, 2025 in Düsseldorf, showcased the latest breakthroughs in tooling, molds, dies, and auxiliary systems for injection molding and extrusion.
This year’s exhibitors focused on enhancing part quality, improving energy efficiency, shortening process cycles, and minimizing production downtime, illustrating a decisive step toward precision, automation, and sustainability in polymer processing.
Extrusion Dies, Heads, and Tooling Systems
In the extrusion sector, several key innovations stood out.
Reifenhäuser unveiled its PAM 2.0 system — a next-generation smart die technology that automatically controlled both the die and feedblock, enabling the reproduction of multilayer structures at the push of a button. This system stabilized layer thickness profiles and minimized manual intervention.
Guill Tool presented three major advances for pipe extrusion:
- Cam-Lock, allowing quick separation of the tip and deflector to reduce cleaning time.
- Rotary Die, rotating the tooling relative to the polymer flow to improve wall strength while reducing thickness.
- Single-Point Concentricity Adjustment, enabling precision alignment within 0.008 inches per rotation through a single-screw mechanism.
KraussMaffei demonstrated its patented KM-3L RK 42-HP coextrusion head, which permitted the use of 100% recycled material in the middle layer. Its unique 1:8 distribution geometry ensured uniform flow and eliminated weld lines on the inner surface.
Oerlikon HRSflow showcased a suite of innovations in hot runner technology, including:
- STARgate HRS for minimizing pressure drop and cycle time,
- GLOW HRS for direct injection with halo-free surfaces,
- Up Nozzle for lightweight and compact part geometries, and
- FLEXflow HRS, which utilized servo-driven needle control to achieve consistent color and dimensional stability in multi-cavity molds.
Meusburger introduced a new series of demoulding components featuring updated mechanical and hydraulic designs that accelerated part ejection and improved safety.
Material Handling and Drying Systems
In material feeding and drying, Qlar presented its SIMPLEX FB gravimetric dosing system, capable of precise multi-component dosing of challenging materials such as post-consumer flakes and reinforced fibers. Integrated sensors monitored fill level and moisture, ensuring process stability.
Motan unveiled its new swift series, a highly energy-efficient chain for drying, conveying, and dosing. The GRAVIFLOW system measured flow rates up to 1500 kg/h, improving accuracy and reproducibility, and featured modular integration with central control systems.
Edwards Vacuum showcased dry EDC and EDS vacuum pumps and the EXDM degassing system for extrusion, offering oil-free, low-maintenance operation. Its Polycold MaxCool technology, with a high water vapor pumping capacity, significantly reduced line downtime.
In deodorization of recycled polymers, NGR and Kreyenborg collaborated on a hybrid solution combining Power Venting and the IR-Fresh Conditioner, achieving substantial reductions in volatile compounds and odor emissions.
Within the pelletizing sector, Starlinger presented the recoSTAR dynamic art and PET art lines, optimized for bottle-to-bottle recycling. These systems achieved 25% lower energy consumption and 15% higher output, becoming highlights of the recycling area.
CGC Technology introduced the UWP Intelligent Underwater Pelletizer, bringing a new level of automation to underwater pelletizing. With a closed water circuit and self-cleaning filter, it reduced energy consumption by up to 30%.
Monitoring, Measurement, and Quality Assurance
Quality assurance tools played a major role at K 2025.
Kistler presented ComoNeo 7.0 with Multiflow technology, which automatically adjusted hot-runner nozzles in multi-cavity molds. Real-time pressure and temperature monitoring corrected process deviations and reduced material waste.
The NCFQ 2166A module, with a piezoelectric force sensor up to 500 N, was developed for precise assembly of sensitive components.
IKV introduced a system for inspecting calender rolls in flat film lines, detecting deposits by gloss measurement and triggering immediate cleaning commands.
Progressive Components launched the CVe Access Monitor with Bluetooth connectivity, enabling wireless recording of mold life cycles and predictive maintenance alerts.
HBK introduced a force transducer with IO-Link interface, allowing real-time monitoring of tensile and compressive forces in the 500 N to 200 kN range.
In dimensional control, Mahr enhanced in-line precision with the MaraMeter 36B digital gauge, while Kautex, in cooperation with InoEx, exhibited a radar-based wall thickness measurement system that enabled real-time distribution control during blow molding.
Robotics and Thermal Systems
In automation and part handling, WITTMANN showcased the Primus 118 robot, featuring 8 kg payload, multi-circuit vacuum, and R9 control system fully integrated with injection molding machines. The SmartRemoval function minimized demoulding time.
ENGEL introduced the next generation of viper robots with modular architecture and 48V control electronics. The iQ motion control technology optimized movements, shortening cycle times.
In mold temperature control, WITTMANN launched the Tempro basic 120, a single-circuit system operating up to 120°C, equipped with a high-flow radial pump and servo-proportional valve for ±1°C temperature accuracy.
Moog presented a newly patented pump architecture, capable of switching between hydraulic, electrohydraulic, and electrohydrostatic modes, ensuring faster response and reduced energy consumption in injection processes.
In polymer welding, Evosys Laser introduced the EvoWeld Mini, a compact desktop system with real-time absorption monitoring. Its counterparts, Evo2Step and EVO 0800-TD, demonstrated improved weld quality and joint strength in complex applications.
In calendering, Comerio Ercole unveiled an innovation that enabled on-the-fly roll embossing changeover, enhancing operator safety and reducing waste.
Software-Driven Process Engineering
Among process engineering tools, SIGMASOFT released version 6.2 of its simulation software, featuring an optimized computational core that quadrupled simulation speed.
New modules such as SIGMAecon for energy and cost analysis and Rubber Designer for elastomer compound design extended its virtual engineering capabilities.
Conclusion
The innovations in tooling and equipment unveiled at K 2025 demonstrated that the future of polymer processing rested on three strategic pillars:
- Precision and process stability through intelligent dies, hot runners, and sensors,
- Energy and material efficiency enabled by dry pumps, advanced thermal circuits, and closed-loop cooling systems,
- Production flexibility through modular design, rapid tooling changeover, and full automation.
Together, these advances outlined a clear vision for the factories of the future — compact, energy-efficient, highly precise, and driven by intelligent tools that adapt dynamically to production demands while advancing the path toward sustainability and smart manufacturing.
