KraussMaffei Showcases Polyurethane Reaction Technology and Injection Molding-Extrusion Synergy at K Show to Lead a Sustainable Future

As the only supplier in the world capable of providing a complete polymer processing chain solution, KraussMaffei consistently leads the industry's future with innovation. At the K 2025 exhibition, KraussMaffei showcases two major innovative breakthroughs by deeply integrating advanced polyurethane processing techniques with injection molding and extrusion technologies—ColorForm in-mold painting technology and glycoLine PU purification technology.

With increasingly stringent global environmental regulations on coating, the ColorForm polyurethane spray technology, which has been on the market for 15 years, is now facing unprecedented development opportunities. At the exhibition, KraussMaffei and its partner Leonhard Kurz will demonstrate the efficient integration of ColorForm with film decoration systems through an innovative in-mold film thermoforming concept. This technology will be showcased at the Leonhard Kurz booth (Hall 5 / A19). You are welcome to experience the live demonstration of KraussMaffei GXW 650 (with rotary table) producing a 720 mm long three-component automotive headlamp part.

0.1 millimeter, knowing the subtlety of "lacquer"

KraussMaffei's ColorForm technology seamlessly integrates reaction molding equipment with injection molding technology, allowing for the direct application of a polyurethane coating on thermoplastic parts within the injection mold. This system supports a high degree of customization in color and texture, and features a self-healing surface function, significantly expanding the possibilities for product design and functionality.

This technology enables high-precision coating control at the 0.1-millimeter level, offering a wide range of special effect finishes and adjustable tactile sensations to meet diverse aesthetic and texture requirements. In addition to excellent chemical resistance, ColorForm also features surface micro-scratch self-repair capabilities, significantly enhancing component durability. Its unique optical depth effect further imparts a distinctive and captivating visual appeal to the product.

The KraussMaffei metering machine offers a maximum flow rate of up to 500 grams per second, efficiently meeting the production demands of large components. The addition of a professional color-matching unit further ensures that automotive interior and exterior parts meet stringent design standards in terms of color and texture. Customers can benefit from a complete turnkey solution, ranging from injection molding machines and polyurethane metering systems to fully integrated automation, enabling reliable one-stop production.

Green Transition of High-Impurity Polyurethane

Purifying glycoLine PU technology to establish sustainable recyclingThrough the extruder in the continuous chemical process, polyurethane components from discarded products like refrigerators are converted into materials containing recycled content.Polyol(rPolyol), which can be used as a starting material for new applications and can be processed in the metering unit without any adjustments.

Currently, the disposal of refrigerator insulation polyurethane largely relies on incineration for energy recovery (such as in cement production). However, with the tightening of global policies on heat recovery, this traditional method faces severe challenges. KraussMaffei, together with BASF, Rampf (a sustainable regenerated polyol producer), and Remondis (a waste electrical appliance processor), is jointly advancing the industrial application of a continuous chemical depolymerization recycling process for polyurethane.

In the purification process of glycoLine PU, a co-rotating twin-screw extruder (ZE BluePower) is used, which can process refrigerator polyurethane foam from the Remondis recycling plant in just a few minutes. This process remains stable even with impurity levels as high as 30% (including other plastic and metal residues).

Through the RAMPF-optimized ethylene glycol depolymerization process, polyurethane recyclate is thoroughly mixed with depolymerizing agents and additives in the extruder. KraussMaffei Innovation Center has further optimized the polyol filtration process through extensive testing to meet high market standards. The resulting recycled polyols can be used as raw materials for BASF’s innovative polyurethane systems to produce high-quality rigid foams containing recycled content.

This technology not only significantly improves the recycling rate of materials but also has achieved commercial economic viability, providing a truly feasible industrialization pathway for the polyurethane circular economy.

Precise Measurement, Intelligent Control for the Future

The brand-new RimStar measuring machine empowers operational innovation through digitalization, featuring a user-friendly interface that significantly lowers the usage threshold and lays a solid foundation for future autonomous operation.

At the K Show, you will witness a complete live demonstration of beverage insulation foam materials processed with polyurethane systems containing recycled content. The KraussMaffei Reaction Process Machinery team will also showcase the RimStar series metering machine equipped with multiple new features. Through comprehensive digital upgrades, this equipment is now fully prepared for autonomous operation.

By integrating digital analysis tools such as dataXplorer, the system can automatically collect and evaluate all key process parameters. Based on these in-depth data analyses, future production systems will achieve automatic adjustment of process parameters and gradually realize unmanned operation in specific procedures, continuously advancing the progress of intelligent manufacturing.

KraussMaffei

Always uphold the "Pioneer Plastic" spirit.

With exceptional technology, we help you achieve a perfect future.

Performance. Perfected. For you

Welcome to the KraussMaffei K 2025 booth.

Hall 15, Booth C24