As the scope of human ingenuity continues to expand, we find ourselves demanding more of our materials, and when it comes to providing versatility, plastics stand far above the alternatives. For compounders, the market demands of today are more varied and intense than ever with many converters and OEMS asking that materials be lighter, tougher, cheaper, and more sustainable all at once. As a result, plastics constantly need to be reshaped to serve a diverse range of rapidly evolving industries.

AMI’s Compounding World 2025 will capture the cutting edge of compounding innovation – examining how formulators and additive producers are rethinking their products to create unique performance profiles, while also navigating ever-shifting regulations and sustainability targets. Nestled amongst exhibition booths showcasing the offerings of leading companies, attendees will find the Compounding World theatre. Here, innovators and thought leaders from across the industry will take to the stage to disseminate details of their latest work and delve into the impact that is could have (or is already having) on our world.

Among the innovators joining the stage for this event are US Silica, a global mining company that also works in the development of specialist industrial materials. In their presentation, Lifeng Chen, Principal Scientist, presents the company’s work in developing a replacement pigment for Titanium Dioxide. TiO2 has long been one of the most common white pigments used in plastics but price volatility and increasing concerns around its toxicity are leading to a desire for convincing alternatives. In response to this, US Silica have been working to develop and test solutions that can maintain the performance of TiO2 while reducing formulation cost. Lifeng covers the fundamental chemistry of their latest alternative and details its application as a TiO2 replacement in both LDPE and PVC. They also highlight the importance of domestic additive production in ensuring reliable supply chains and, ultimately, reducing business risk.

Another speaker seeking to re-think additive technology is Hiroyuki Fukushima, General Manager of Plastics Additives at Sanyo Chemical America. His presentation examines the problem of static, a pervasive issue that has impacts ranging from reduced paint quality and dust contamination all the way to component damage and explosions. Hiroyuki outlines the problems with current solutions, such as surface active agents or conductive materials, and presents resin incorporated agents as an alternative, highly compatible, permanent antistatic solution that has minimal impact on mechanical performance. He will elucidate the mechanism and performance of this technology using lab data, and envision applications for this promising new solution.

Beyond showcasing new additive technologies, the compounding theatre will also provide compounders with take home solutions to the problems they currently face during day-to-day operations. One example of this comes from Ron Van Ostenbridge, Business Development Manager at Coperion, who investigates how smart feeder choices can reduce the risk of failure during the compounding process. Ron will highlight the importance of pre-process testing and developing an understanding of your process, recipe, and materials. He will then goes on to look at the issues faced on the factory floor and how careful installation, data monitoring, and preventative maintenance can reduce issues both today and in the future.

Another emerging technology improving compounding performance and R&D lead time is artificial intelligence. Across all industries, AI and machine learning (ML) are revolutionizing processes and improving efficiency, and the plastics compounding space is no exception. To explore the role of AI in enabling rapid innovation, predictive accuracy, and process optimization, Professor João Maia of Case Western University take the stage. Along with giving a background on the current technical state of AI and ML in plastics development, Professor Maia will also share some recent case studies. João will present details of how ML and AI are driving real-time quality control of blown film using recycled plastics, and how ML can be employed to optimize catalyst design for twin-screw extrusion catalytic cracking of polyolefins.

The above talks demonstrate that innovation in the compounding space is moving rapidly and, as such, it is important for companies to find and retain top talent. However, with many members of the plastics industry reaching retirement age, and a negative public image, remote plant locations, and a more diverse job market discouraging young people from entering the plastics space, the industry faces an existential challenge. To discuss this issue, Jennifer Markarian, Contributing Editor of AMI magazines host the panel “Futureproofing the workforce – skills, talent & training in the compounding sector”. Jennifer will be joined on stage by Cass Birchbauer, Chief Human Resources Officer at Chroma Color, Ginny Wilczak, Partner at TAMS Group, and Michael Merolla, HR Manager Northeast at Americhem, to discuss the problems they’re experiencing with recruitment, the steps they’re taking to overcome these problems, and the role of technology in finding and securing the right candidates. The panel will also explore shifts in industry values and general strategy from the past to the future, and examine the role of company culture in future proofing.

AMI’s Compounding World Expo is a free to attend event that attracts thousands of professionals from across the plastics supply chain for two days of discussion, discovery, and networking. To benefit from all of the talks at the event and the extensive opportunities to connect with colleagues, customers, and clients, please book your place at the event now.