Looking Back at 2025

Anniversary, Innovation, and Global Presence: Looking back at 2025 

As we look back on the past months, we are filled with pride and gratitude. This year has been rich in meaningful moments and progress: we reaffirmed our high quality standards, successfully implemented great customer projects, and celebrated our company anniversary. Equally valuable to us were the personal interactions — the many inspiring conversations at trade fairs and events, the global connections we established, and the strong sense of togetherness within our team.

5 Years of Polytives

In March, we celebrated our fifth company anniversary. Looking back, it has been an incredible journey marked by growth, change and many achievements. Since our official founding in March 2020, our team has continuously evolved and gained invaluable insights. Together with our partners and customers, we have pushed the boundaries of polymer innovation time and again. This innovative drive is also reflected in our most recent projects – and is shaping the path we will continue to take in 2025.

Forward-Looking Projects and Proven Quality

In cooperation with Brac-Werke and Nordmann, we demonstrated that our additives help reliably process even technically demanding materials such as recycled PET. The results were published in the renowned Kunststoff Magazin. Another highlight was the successful increase in efficiency and design freedom in the processing of PLEXIGLAS® from Röhm GmbH – with long-term stability.

We also achieved an important technological breakthrough in the field of biopolymers, even though much of the work had already been completed in 2024: Together with our partner TITK e. V., we published results on PHA processing that clearly show how significantly the processing can be facilitated – paving the way for new, sustainable applications.

Late spring saw the launch of two new projects with a strong focus on recycling and circular economy. The project ReEnAdd – in cooperation with TU Ilmenau and KOMOS – aims to improve energy efficiency and recycling quality through the use of new additives. At the same time, the project BiKoPow (in collaboration with Lean Plastics Technologies GmbH and TITK e.V.) focuses on additive manufacturing. With these initiatives, we are consistently strengthening innovation, efficiency and sustainable solutions for the plastics industry.

A major team success was the completion of our ISO 9001:2015 re-certification audit. As in previous audits, there were no notable findings – a result our small team is particularly proud of. We continually work on optimising our processes, and we validate our high quality standards through regular material testing. Using so-called xenotests, we examine the ageing behaviour of plastics (yellowing, loss of transparency, surface wear), especially for outdoor applications. In this way, we ensure the reliability of our polymer additives even under demanding conditions.

Our Trade Fair Highlights: From KPA to K – and Around the World

Direct exchange with the global plastics community is especially important to us. Accordingly, we were once again present at numerous trade fairs and events this year, with the K-show in Düsseldorf standing out as a particular highlight: It all began here in 2022 with the introduction of our first product. This year’s response was overwhelming. The strong interest in our solutions and the many inspiring conversations left a lasting impression.

As a co-exhibitor with our partner Nordmann, we also took part in RePlastEurasia in Istanbul and the well-attended PRSE in Amsterdam. Thanks to our partner Kangshin, our technology was also showcased at KOPLAS in Korea – an important step in strengthening our position in this dynamic region.
KPA and KUTENO in Bad Salzuflen once again convinced us with excellent networking opportunities, a relaxed atmosphere and a new location. To extend our reach beyond physical trade fairs, we also participated digitally: with a short presentation at the INDUSTRY.forward EXPO. Our trade fair season concludes in December with PlastEurasia in Istanbul.

Customer Proximity and New Partnerships in Asia

We continue to build valuable partnerships across the globe. Especially in Asia, we strategically expanded our market presence and established important new collaborations. In spring, together with PolymerMat e.V. – the plastics cluster of Thuringia – and BASF Performance Polymers, we organised the association’s first PolyTour. As part of this initiative, we welcomed our Japanese partner Sanyo Trading as an honoured guest in Rudolstadt to deepen the collaboration and strengthen the mutual understanding.

These encounters not only strengthened regional networks but also created a solid foundation for further market development in Asia.

Shaping & Connecting: Our Engagement in the Plastics Industry and Beyond

We are proud to be part of a broad plastics and start-up ecosystem in which we share expertise and learn from one another – whether through formal committee work or at specialised industry events.
Our management team is actively engaged in various honorary roles that extend far beyond our own company and contribute directly to the economic, scientific and social development of our region. Viktoria Rothleitner strengthens start-up support and women’s entrepreneurship as a board member at ThEx innovativ and StarTH, and supports the EXIST-Women programme. Oliver Eckardt brings the industry perspective into strategic committees such as the SANS-F Industrial Advisory Board and the IHK Committee for Industry and Research.

We also maintained close professional exchange within the industry: The TecPart annual conference in Heilbronn offered the ideal opportunity to connect with leading plastics processors. The Central German Plastics Day in Halle (Saale) provided an important platform for discussing the future of the plastics industry, bringing together industry, policy and research. Our CTO and co-founder, Oliver Eckardt, contributed on site.
We used numerous other forums for networking: At the ECP Industry Speed Dating we engaged with potential customers and partners and reconnected with familiar faces. The 14th Materials Seminar in Rothenburg ob der Tauber offered deep insights across the plastics sector. As part of the Jena delegation at the East German Economic Forum (OWF) in Bad Saarow, we moved important future topics for Thuringia forward together with partners such as JENA Digital and Fraunhofer IOF. At the ThEx Zukunftswirtschaft Conference in Jena, co-founder Viktoria Rothleitner shared practical insights on how companies in Thuringia can integrate sustainability into their daily operations.

Whether at team events such as archery and brewery tours, at trade fairs or through co-organising the PolyTour – our team grew even closer together this year.

We carry this positive momentum forward: While ongoing projects reach their milestones and new ones successfully take off, we set our sights on the next goal – making our polymeric additives the standard in even more demanding applications.

Polymer additives for PMMA optimisation

polymer additives for PMMA optimization

How Polymeric Additives Are Revolutionizing PMMA Processing

Rising demands for resource efficiency, energy savings, and stable, high-performance manufacturing mean that even established materials like PMMA (polymethyl methacrylate) must reach new levels of performance. Plastics processors are looking for greater design freedom, improved flow behavior, shorter cycle times, and stable material properties—while also meeting regulatory and environmental requirements.

A recent collaboration between Polytives and Röhm demonstrates the enormous potential of modern polymeric additives. By using the polymeric processing aid bFI A 3745, PMMA compounds can be specifically optimized—without compromising optical or mechanical properties.

Challenges in PMMA Processing and Why Additives Matter

PMMA is a well-established technical material, but new product generations demand:

  • more filigree component geometries
  • higher flowability
  • lower processing temperatures
  • reduced cycle times
  • stable optical performance

The solution lies in fine-tuning the material—without changing the chemical structure of the base polymer. This is exactly where the Polytives additive comes into play.

The Polytives Additive: Hyperbranched PMMA for Superior Processability

The additive bFI A 3745 consists of hyperbranched PMMA whose molecular architecture significantly improves melt dynamics.

Key advantages include:

  • reduction of melt viscosity
  • improved flowability
  • lower processing pressures and temperatures
  • gentler, more energy-efficient processing
  • no migration thanks to polymeric structure
  • full optical transparency remains intact

The effect becomes apparent at low dosage levels— even at 10% additive content, mechanical properties remain strong.

Measurable Improvements in Industrial Processing

Project data clearly shows how significantly PMMA compounds can be improved:

  • temperature reduction of 10°C to over 35°C
  • pressure reduction of up to 50%
  • cycle time reduction of more than 20%
  • MVR increase up to 100% (doubling)

For applications with strong cost and energy constraints—such as injection molding or compounding—this delivers an immediate competitive advantage.

No Compromises in Optical Quality or Long-Term Stability

Optical quality is essential in many PMMA applications. Testing confirms:

  • no impact on transmission (200–800 nm)
  • no significant yellowing (YI < 5)
  • 10,000-hour weathering stability with no optical degradation

This makes the additive suitable for applications requiring high transparency and UV stability.

Why Modified PMMA Compounds Make a Difference

With the help of polymeric additives, existing materials can be improved without introducing completely new material systems. The benefits include:

  • fast integration into existing production lines
  • lower transition risks
  • improved performance without design limitations
  • more economical processes through shorter cycles and reduced energy consumption

This technology provides plastics processors with new opportunities to produce high-quality PMMA components more efficiently and more sustainably.

Conclusion: Polymeric Additives Are the Key to Energy-Efficient PMMA Processing

The project clearly demonstrates the potential of purpose-designed polymer additives. With bFI A 3745, PMMA compounds can be modified to enhance both processing performance and sustainability—without sacrificing optical clarity or mechanical strength.

For companies looking to modernize their production processes, polymer-based additives offer a future-ready and economically attractive solution.

FLYER USE CASE

PMMA

Polytives at K 2025

Looking Back at K 2025: Our Journey in Düsseldorf

After an intense week full of inspiring talks, new connections, and shared visions for a more sustainable plastics industry, we’re taking a moment to look back at our experience with Polytives at K 2025 in Düsseldorf.

When we arrived on October 7 – the day before the official start of the fair – we already knew this week would be something special. A networking evening in the heart of the city offered the perfect kick-off: inspiring conversations, first familiar faces, and new connections that set the tone for what was to come.

A Flying Start

From the very first morning, Polytives at K 2025 took off at full speed. We had scheduled more than 40 meetings in advance – but by the end of the fair, we had spoken with more than 300 people. Incredible!

Our booth in Hall 7a, as part of the TecPart joint stand together with Cirplas, Schwarz Plastic Solutions, KMA, and Voelpker, was initially manned by Oliver Eckardt, Steffen Felzer, and Viktoria Rothleitner. On Sunday afternoon, Oliver Guntner joined the team to support the second half of the fair.

While Sunday brought a quieter atmosphere, Monday once again saw a strong surge of visitors – and by Tuesday, the booth was buzzing with discussions until the very end.

When we finally packed up our exhibition pieces and tapped the last few drops of our Watzdorfer beer from the barrel on Wednesday afternoon, we did so with a big smile and full hearts.

Thank You for Your Interest and Trust

We want to express a sincere thank you to everyone who stopped by, who took the time to talk to us, and who shared their ideas and challenges. We were truly impressed by the openness and curiosity of so many international visitors who had travelled long distances to meet us, often more than once.

It was equally rewarding to meet people who had no prior connection to us but were drawn in by curiosity or recommendation. Hearing visitors this year say they came “because someone recommended Polytives” was a proud and motivating moment for our team.

Across the many conversations throughout the week, one topic kept coming up again and again: How to make recyclate processing more efficient and reliable. The topic of recyclate processing clearly continues to gain momentum, and it’s exciting to see how many companies are actively seeking practical and long-term solutions.

We are deeply grateful to both our long-standing partners and our new collaborators for their trust and openness. Your feedback and joint projects are what keep us moving forward – and we can’t wait to see what’s next!

Tradition Meets Celebration

Or: A Little Fun Never Hurts

Every three years, the K show brings the plastics industry together for an entire week of exchange, innovation, and inspiration. And with it comes a certain rhythm that many of us know and love. That includes the traditional Exhibitors’ Party on Saturday night, which once again in 2025 – the 76th year of K – marked a fitting celebration after the first week of the show.

Exceptional food, great entertainment, and a dance floor that filled up quickly – the perfect way to wrap up intense and inspiring days at the fair.
And yes, we decided not to share photos from that night – the memories will do just fine!

Looking Ahead

Polytives at K 2025 once again showed how valuable personal exchange and strong networks are for driving innovation in the plastics industry.

We’re already looking forward to the next milestones – and maybe to seeing you again soon at PlastEurasia, PlastIndia, or one of the regional trade shows such as KUTENO or KPA.

If we missed each other at the fair, feel free to reach out under the subject “K 2025” via info@polytives.de – or through your familiar contacts and channels.
We’re always happy to continue the conversation!

How polymer additives can improve the processing of PMMA

How polymer additives can improve the processing of PMMA

Why Polymeric Additives Are Now in the Spotlight

The plastics industry is undergoing a transformation — driven by sustainability, energy efficiency, and material innovation. Polymeric additives offer a solution that combines resource conservation with process enhancement.

PMMA Under Pressure – Challenges in Processing

Plexiglas® (PMMA) has long been a trusted material, but modern requirements demand more: finer component geometries, lower processing temperatures, and shorter cycle times.
The Polytives additive bFI A 3745, based on acrylate chemistry, addresses these challenges by precisely improving flowability and process stability.

What Is a Polymeric Additive – and Why Is It Different?

Structure and Functionality

The additives from our bFI family are themselves polymers, not conventional auxiliary substances.
Their hyperbranched PMMA structure integrates completely into the polymer matrix — without migration and without loss of transparency.

A Sustainable Alternative to Conventional Additives

Unlike PFAS- or silicone-based additives, Polytives additives are recycling-friendly and meet all relevant regulatory requirements — offering a future-proof and environmentally responsible option.

Measurable Benefits in Practice

In tests with PMMA compounds, the following improvements were achieved:

  • Temperature reduction: up to 35 °C

  • Pressure reduction: up to 50 %

  • Cycle time reduction: more than 20 %

  • Flowability doubled (MVR value)

These results clearly demonstrate how polymeric additives can enhance processing efficiency and reduce production costs.

Long-Term Stability Confirmed

A xenon weathering test over 10,000 hours showed:
no yellowing, no haze formation, and constant light transmission in the visible range (400–800 nm).
Our additives fully preserve the optical quality of PMMA while simultaneously improving process performance.

Molecular Architecture – The Science Behind the Success

The secret lies in the hyperbranched molecular structure:
it increases the mobility of linear PMMA chains in the melt, thereby lowering viscosity and enhancing material flow.
Even small dosages — as low as 1–3 % — produce significant, visible effects.

From the Lab to the World – Polytives Expands to Japan

The success of the polymeric additive has attracted international attention.
Polytives is expanding its activities in Japan, bringing energy-efficient additive technologies to the global stage.

Conclusion – Polymeric Additives as the Key to Sustainable Plastics Processing

Polytives demonstrates that the future of the plastics industry lies not only in new materials, but in intelligent additives that make existing materials more efficient and environmentally friendly.
Polymeric additives are emerging as a central driver of sustainability, performance, and innovation in modern plastics processing.

FLYER USE CASE

PMMA

Polytives expands to Japan: Innovative polymer additives meet Japan’s high-tech plastics industry

improving PMMA processing

A Strategic Step into a Technological Powerhouse

For Polytives, a technology company from Thuringia, Germany, the journey to Japan marks a milestone in its international expansion. With a polymer additive platform designed to improve efficiency, energy use, and process stability in plastics manufacturing, Japan represents an ideal growth market.

Although Japan’s plastics market, at 9 million tonnes annually, is smaller than those of China or North America, it stands out for its technological sophistication and innovation potential. More than 45% of processed plastics in Japan are used in technical applications — nearly double the global average.

Building Bridges Between Innovation and Culture

Successful collaboration, says Polytives CEO Viktoria Rothleitner, requires more than digital meetings — it needs personal interaction and cultural understanding.
During a delegation trip to Tokyo, Osaka, and Kyoto, Rothleitner and her team participated in the Innovation Leaders Summit (ILS), a matchmaking platform that connects start-ups with major industry partners.

The trip resulted in valuable partnerships, including early discussions with Sanyo Trading and Mitsubishi. What stood out most, however, was Japan’s structured and respectful communication style — fact-based, efficient, and highly professional. Meetings were well-prepared, precisely timed, and marked by mutual appreciation.

Lessons from Japan’s Industrial Culture

Polytives gained deep insight into how Japanese companies operate:

  • Broad diversification across industries under one corporate umbrella

  • Strong focus on precision, quality, and long-term cooperation

  • Growing commitment to sustainability and circular economy

Japan’s approach to sustainability is young but highly determined. From bio-based materials to surface coatings with recycled fillers — the market is actively exploring environmentally conscious innovations.

Why Japan Is the Right Market for Polytives

Polytives’ polymeric additive technology is particularly well suited to Japan’s engineering plastics sector, which values long-term partnerships, performance optimization, and technological clarity.

The company’s bFI additive platform improves flowability, reduces pressure and temperature requirements, and boosts energy efficiency — all crucial for Japan’s precision-oriented plastics manufacturers.

To ensure a strong market entry, Polytives has launched a pilot phase with defined resources, measurable KPIs, and a local distribution partner. Several initial projects are already underway, showing excellent results and collaboration.

Learning from a Market That Values Respect and Precision

“Japan has shown us how efficient global cooperation can be when it’s built on preparation, respect, and shared curiosity,” says Rothleitner.
The experience reinforced Polytives’ belief that technological progress and cultural understanding go hand in hand.

While every market is different, the principles of process optimization and energy-efficient production remain universal. Polytives’ platform technology delivers exactly that — now also for Japan’s advanced plastics industry.

Conclusion: From Thuringia to Tokyo – A Shared Vision for Sustainable Plastics

The expansion into Japan underlines Polytives’ global ambition: combining German innovation with Japanese precision to shape the future of sustainable plastics processing.

Through intelligent polymer additives, the company is proving that the next generation of materials innovation lies not only in new polymers, but in smarter chemistry that makes existing materials more efficient, sustainable, and globally adaptable.

About Polytives:
Founded in 2020, Polytives develops polymer-based additives that optimize flow behavior and energy efficiency in plastics processing. These innovative additives integrate seamlessly into polymer matrices, enabling sustainability and performance without compromising material properties.

🌐 www.polytives.com

Peroxides and antioxidants in plastics

peroxides and antioxidants in plastics

Speeding up and slowing down at the same time? Peroxides and antioxidants in plastics do not mix

In plastics processing, additives are generally indispensable for controlling processability and material properties. Two well-known classes of additives are peroxides and antioxidants in plastics – both fulfill essential but contradictory tasks. Their combined use is therefore problematic. In the following, we will briefly examine what additives do, where the problems lie, and what role polymer additives can play.

Antioxidants: A protective shield against oxygen

Oxygen is a so-called diradical that reacts with polymer chains and triggers degradation reactions. This process is accelerated, especially in combination with UV radiation.

  • The result: embrittlement, discoloration, and a loss of mechanical properties.
  • The solution: antioxidants that act as radical scavengers for oxygen. They bind free radicals and thus prevent the polymer chain degradation that oxygen would trigger. A typical example of such an antioxidant is butylated hydroxytoluene (BHT).

Peroxides: An effective tool for improving flow

Peroxides, on the other hand, are used specifically to break down polymer chains. This reduces the viscosity of the compound and makes it easier to process. In other words, degradation reactions are used to improve flow.

  • How it works: Peroxides break down into radicals. These radicals trigger controlled chain degradation during processing.
  • The conflict: The effect is canceled out when antioxidants and peroxides are used simultaneously. Peroxides and antioxidants in plastics are therefore also referred to as antagonists in this context.

Conflicting modes of action lead to conflicts

Antioxidants neutralize radicals, while the effect of peroxides is based on the formation of radicals. The result: when the two are combined, their effects cancel each other out. The flow improvement provided by the peroxides does not occur, and the oxidation protection provided by the antioxidants is significantly weakened. As a result, the objectives of the additives are not achieved – their use is simply not effective, neither for peroxides nor for antioxidants.

A straightforward alternative: additives without a radical mechanism

Polymer additives such as those from Polytives can be used to circumvent the dilemma described here. They are not based on peroxide technology and therefore do not interact with antioxidants or UV stabilizers. The result:

  • Improved flow without compromise
  • Preservation of the protective effect of antioxidants
  • Compatibility with polyolefins

This enables efficient and sustainable plastics processing without the disadvantages of conventional peroxide systems.

Conclusion

The tension between peroxides and antioxidants in plastics illustrates how complex plastics processing can be and how much new approaches are still needed. Polymer additives represent one such new and innovative approach. Talk to us about how they can be used to develop new solutions for your applications.

Trends in plastics processing

trends in plastics processing

Trends in Plastics Processing: How Polymeric Additives from Polytives Open New Possibilities

The trends in plastics processing are shifting faster than ever. Energy efficiency, sustainability, and economic stability are becoming essential for companies navigating competitive markets and increasingly strict regulations. At the same time, material fluctuations and cost pressures create challenges for processors who aim to integrate recyclates, biobased compounds, and efficient production workflows.

This is where polymeric additives from Polytives come into play. They provide a technological solution that stabilizes processes, improves efficiency, and conserves resources—without compromising the mechanical properties of the base polymer.

Between Goals and Reality: Challenges in Modern Plastics Processing

The plastics industry faces multiple simultaneous pressures:

  • rising energy costs
  • stricter regulations
  • increased global competition
  • demand for more sustainable materials such as recyclates and biobased compounds

In practice, however, fluctuating raw material quality, narrow processing windows, and additional material costs make sustainable transformation difficult. Many companies find themselves caught between ambitious goals and economic constraints.

A Versatile Tool: Polymeric Additives That Match the Trends in Plastics Processing

Polytives’ polymeric additives stand out from conventional additive approaches. Since they are polymers themselves, they preserve the mechanical properties of the host material. They are also:

  • compatible with a wide range of virgin and recycled plastics
  • migration-stable and regulatory-safe
  • suitable for diverse applications and processes

This combination of technical effectiveness and regulatory clarity aligns seamlessly with current trends in plastics processing: producing more sustainably, safely, and economically while maintaining high material quality.

Simplifying Processes and Reducing Costs

The core effect of Polytives additives is the significant reduction in melt viscosity. As a result:

  • materials process more easily
  • pressure and temperature requirements drop
  • machine utilization improves
  • cycle times decrease
  • equipment experiences less stress

For processors, this means:

  • lower energy consumption
  • reduced downtime
  • greater flexibility in machine selection
  • direct cost savings
  • an improved CO₂ footprint

These advantages directly reflect some of the most important trends in plastics processing today.

More Design Freedom Without Losing Material Performance

Lower processing temperatures expand the processing window considerably. This allows manufacturers to:

  • gently incorporate temperature-sensitive additives
  • process natural fibers and other biobased components more reliably
  • use higher filler contents
  • explore more flexible formulation and product designs

The result: improved design freedom and greater material versatility—key factors for sustainable innovation in plastics manufacturing.

A Closer Look at Recyclates: Additives as Enablers

Increasing the share of recyclates is one of the major trends in plastics processing—but also one of the most challenging. Variations in material quality and limited processability often hinder implementation.

Polymeric additives can help overcome these barriers by:

  • stabilizing processing conditions
  • compensating for raw material fluctuations
  • enabling higher recyclate content
  • improving overall material behavior—sometimes making processing possible in the first place

A recent example:
With rPET, in cooperation with Brac-Werke AG, polymeric additives improved processability significantly—even without perfect material purity—helping companies integrate more recycled content into their products.

Polymeric Additives as Pioneers for Future Materials

Polytives sees polymeric additives as a platform technology, not a short-term fix. They can be customized for a variety of materials and manufacturing processes, offering:

  • higher production flexibility
  • reduced dependence on fluctuating raw material quality
  • stable mechanical performance under demanding conditions
  • long-term viability for sustainable product development

Within the TecPart e.V. network and through cooperation across the industry, Polytives is actively driving innovation toward more efficient and sustainable plastics processing.

Polytives’ commercially available processing aids have already proven their capabilities in numerous projects—and are ready to support future developments as companies move toward smarter, greener, and more adaptable manufacturing.

FLYER USE CASE

rPET

How can the processing of rPET be optimized from a process engineering perspective?

Processing recycled PET (rPET)

rPET in Focus: Sustainability Meets Technical Limitations

Recycled PET – or rPET – is gaining increasing importance in the plastics industry. Legislative initiatives such as the EU Plastics Strategy and mandatory recycling quotas for packaging are driving its use.
However, the processing of rPET still poses challenges for many manufacturers: even with optimal injection molding parameters, issues like incomplete mold filling, flash formation, or high energy consumption can occur.

A recent industrial case demonstrates how these challenges can be overcome — without longer cycle times or reduced product quality.

The Challenge: Incomplete Mold Filling Despite Optimal Machine Settings

When producing a prototype component made from rPET, Brac-Werke encountered a typical issue: despite optimized temperature and pressure settings, the part could not be completely molded.
Common countermeasures, such as increasing pressure, did enable full mold filling — but also caused flash formation at the gate, leading to costly rework.

Raising the temperature and pressure simultaneously resulted in higher energy consumption, longer cycle times, and accelerated material degradation — all detrimental to process efficiency and sustainability.

The Solution: Polytives bFI A 3745 Additive Enhances rPET Flow Properties

In cooperation with the chemical distributor Nordmann, Brac-Werke implemented a polymeric additive solution: bFI A 3745 from Polytives.
Even a small dosage of 3–5% proved sufficient to significantly enhance the rheological properties of the rPET melt.

Key effects at a glance:

  • Reduced viscosity of the rPET melt

  • Improved flowability and complete mold filling

  • More uniform material compaction

  • Approximately 25% lower injection pressure

  • Reduced energy consumption and machine wear

“The Polytives additive exceeded our expectations — without any compromise in quality or cycle time,”
says Markus Hofer, Managing Director of Brac-Werke.

Process Engineering Optimization for Greater Efficiency and Sustainability

The targeted use of the additive resulted in a more stable, economical, and environmentally friendly production process.
The mechanical performance of the final component remained unchanged, while process stability increased noticeably.

According to Viktoria Rothleitner, Managing Director at Polytives:

“Our additives make it possible to process demanding materials like rPET economically and reliably — a key lever for greater sustainability in the plastics industry.”

Conclusion: Efficient rPET Processing Through Targeted Additive Solutions

This case clearly illustrates how the processing of rPET can be optimized from a process engineering perspective:
By using the right polymeric additives, manufacturers can improve melt flowability, lower energy consumption, and increase process reliability — all without sacrificing quality or profitability.

As a result, rPET becomes a technically and economically viable alternative to virgin polymers such as ABS, opening new opportunities for sustainable component design in the plastics sector.

Source: Polytives – Application Report, Kunststoff Magazin, July/August 2025
www.polytives.com

FLYER USE CASE

rPET

FAQ — How can the processing of rPET be optimized from a process engineering perspective?

1. What is “process engineering optimization” for rPET?
It means adjusting material formulation (e.g., additives), machine settings (temperature, pressure) and mold design to improve throughput, part quality and energy efficiency.

2. How can rPET flowability be improved?
By using targeted additives (polymeric flow enhancers), optimizing melt temperature and shear. Small dosages (3–5%) of suitable additives often yield major improvements.

3. Why is reduced viscosity important?
Lower melt viscosity reduces required injection pressure, improves mold filling, and lowers energy consumption and tool wear — without sacrificing part performance if the additive is chosen correctly.

4. What are the benefits of lower injection pressure?
Lower pressure reduces energy use, machine and tool wear, part warpage and rework from flash — improving production economics.

5. Do additives affect mechanical properties?
If selected and dosed correctly, additives typically do not degrade mechanical properties, but validation (tensile, impact, rheology tests) is recommended.

6. How does optimization improve energy efficiency in plastics processing?
Measures such as reduced injection pressure, shorter cycle times and less rework lower the total energy per part and improve the product’s carbon footprint.

7. What does “uniform compaction” mean?
It refers to a consistent material density across the part without voids or weak spots — achieved through good flow distribution and appropriate holding pressure control.

8. Can rPET replace virgin polymers like ABS?
Yes — with process optimization (additives, parameter tuning) rPET can be a viable substitute in many applications, provided part requirements are met.

9. What first steps should manufacturers take to work with rPET?
Perform material characterization (MFI, moisture), run pilot tests with/without additives, adapt mold and process settings, and conduct mechanical testing and LCA considerations.

Sun, rain, heat – plastics face tough conditions in everyday use

Whether used as housings, lighting elements, protective covers or outdoor furniture – plastics exposed to the elements or intense light must withstand a lot. But how can we tell how well a plastic ages? And how can that be evaluated without waiting for years?

This is exactly where the xenon test comes in: A proven laboratory method that simulates artificial weathering caused by sunlight, heat and humidity. Within just a few weeks, it provides insights that would take years to gather through natural exposure.

What actually happens during a xenon test?

In essence, a material – such as a plastic specimen – is placed into a test chamber equipped with a xenon arc lamp that mimics natural sunlight. The sample is also exposed to defined levels of heat and moisture. It may sound simple, but the combination is highly effective: typical weathering conditions can be simulated in a controlled and accelerated manner.

The goal is to observe how colors, surfaces or mechanical properties change. Does the material become brittle? Does it yellow? Do cracks form? This enables the comparison and optimization of materials, without long-term outdoor testing.

Why is this particularly relevant for PMMA?

A prime example for the use of xenon testing is PMMA (polymethyl methacrylate) – widely known as acrylic glass. It’s crystal clear, lightweight and highly versatile but also sensitive to UV radiation. If PMMA becomes brittle or discolored, both its appearance and functionality may be compromised.

With xenon testing, different formulations or additives can be tested specifically: Which one provides better protection? How long does the material remain optically and mechanically stable? Especially for transparent or colored applications, assessing long-term weatherability is crucial.

What standards apply?

To ensure that xenon tests deliver meaningful and comparable results, they must follow standardized protocols, such as:

  • ISO 4892-2 – for plastics

  • DIN EN ISO 16474-2 – for coated surfaces

  • ASTM G155 – commonly used in North America

These standards define parameters such as light intensity, chamber temperature, exposure duration and humidity cycles.

Why is it worth the effort?

Because it pays off. Testing early in the development process helps manufacturers understand how their products will perform under real-world conditions and enables targeted improvements. For outdoor applications, architectural elements, automotive components or long-lasting consumer goods, this can make a decisive difference.

Conclusion

The xenon test for plastics offers a glimpse into the future: it shows how materials age under realistic conditions and what can be done to improve their durability.

At Polytives, we are incorporating xenon testing into our own material evaluation processes. We’re excited about the insights it will bring – stay tuned!

Focus on sustainability – a brief interview

Focus on sustainability

Oliver, as QMB and as the person in charge of sustainability at Polytives: You have been dedicated to the topic since 2022, so you could say that you lay focus on sustainability. But you’re not obliged to produce a report, are you?

Due to the size of our company, we are still exempt from the reporting obligation. However, we are not primarily addressing the issue due to legal expectations, but because the topic of sustainability is important to us personally on the one hand and is also part of our long-term corporate strategy on the other. For us, sustainability is considered throughout company scaling and product development and is an intrinsic part of how we identify topics and potential.

It was important for us to establish this procedure as early as possible in order to then gradually approach the day-to-day circumstances and the legal framework. For the latter area in particular, a quick start made sense to get a feeling for which data and key figures could be collected. The effort involved in starting from scratch naturally increases as soon as a company is larger at a later stage.

That sounds understandable. Have there also been any external inquiries, although you are not obliged to report?

There certainly were. Being exempt from the reporting obligation does not mean leaving the topic completely unaddressed. Larger companies pass on inquiries within their supply chain and even in the run-up to a prospective collaboration, the players are increasingly focusing on sustainability.

As we are already somewhat active in this field, we can therefore react quickly and purposefully and provide appropriate answers. I think we can definitely say that our customer-centric way of working also creates small competitive advantages for our customers and for us.

If you have been reporting since 2022: What has changed over this period, what have you learned and what is your conclusion?

It was clear to us from the outset that our first report would not be “textbook”. Rather, it was a stocktaking exercise and showed what was possible in a short space of time and with little effort. We were still missing too many data points for in-depth reporting and the dimensions of sustainability had not yet been explored in depth. With the next report, we then knew where we needed to start with improvements and had also found new ways to close gaps. We are still mainly focusing on the ecological and economic aspects of sustainability, as our work and our products can have a significant impact here. For example, in 2023 we had already dealt with carbon accounting for the first time, which is an indispensable part of the report.

Our goal will ultimately be a report that meets a fully-fledged standard in terms of content – there is still a lot to do before then, but the methodology of small improvement steps will also lead us there. For example, we are currently using the VSME model as a guide.

It is generally advisable to start early in all areas, but not too ambitiously, and to grow organically. For example, consulting, networking and general information events have helped us to develop the right speed.

High-quality recycled PP: More potential through optimized flow properties

Versatile Applications

Unlocking the potential of high-quality recycled PP through additives

High-quality recycled polypropylene (PP) plays a crucial role in a functioning circular economy. As an alternative resource, it helps reduce the consumption of fossil-based raw materials and minimizes environmental impact. However, companies often face the challenge that high-quality recycled PP exhibits variations in material properties compared to virgin PP. This is particularly evident in flow properties, which are critical for efficient processing.

By leveraging polymer-based additives, these fluctuations can be effectively compensated. This allows for targeted optimization of high-quality recycled PP, enhancing processability while supporting sustainable manufacturing processes and product designs.

Why Are Flow Properties and Cycle Times Critical for High-Quality Recycled PP?

One of the key differences between high-quality recycled PP and virgin material lies in the melt flow rate (MFR). While virgin PP offers consistent viscosity, recycled PP can vary significantly depending on its source and recycling process. This variability presents challenges in injection molding and other industrial applications.

By improving the flow properties through the use of additives, manufacturers can not only enhance process stability but also reduce cycle times in injection molding. Faster processing leads to more efficient production with lower energy consumption – a key factor in promoting sustainability and reducing CO₂ emissions.

The Advantages of Optimized Flow Properties in High-Quality Recycled PP

Reduced Energy Consumption and Resource Efficiency

Optimized flow properties enable shorter cycle times in injection molding, leading to reduced energy consumption and a lower carbon footprint.

Enhanced Processability

Greater process stability ensures consistent and reliable results in polymer processing. High-quality recycled PP can be more easily integrated into existing manufacturing workflows.

Expanded Application Scope

Improved material characteristics allow for the use of high-quality recycled PP in demanding industries. Applications in the automotive sector and for technical components are becoming increasingly viable.

Lower Scrap Rates, Increased Sustainability

Stable flow properties help reduce production scrap. A consistent material flow ensures uniform product quality, enabling a higher proportion of recycled PP in finished goods.

Contribution to the Circular Economy

High-quality recycled PP helps reduce reliance on virgin plastics. Sustainable production methods, combined with optimized cycle times and energy-efficient processing, support companies in achieving their environmental goals. Additionally, reduced thermal stress and shorter processing times preserve material integrity, ensuring better quality for subsequent recycling cycles.

Conclusion: Additives Enhance the Competitiveness of High-Quality Recycled PP

To increase the share of high-quality recycled PP in industrial applications, technological innovations are essential. Additives improve melt flow properties, shorten cycle times in injection molding, and ensure consistent, high-quality output. This makes high-quality recycled PP not only a sustainable choice but also an economically attractive alternative to virgin plastics.

5 Years Polytives GmbH

AI-generated picture

5 Years Polytives GmbH: How it all started, where we are now, and what’s next?

The Beginning: When Polytives Was Still “Hyperflow”

When chemist Oliver Eckardt and Prof. Felix H. Schacher decided in 2014 to shape the topic of Oliver’s dissertation and commenced their research, neither of them anticipated that this would ultimately lay the foundation for the establishment of Polytives.

Originally initiated as a ZIM project at Friedrich-Schiller-University in Jena, it soon became clear that their developed technology had immense potential — too much to not at least attempt to bring it to market maturity. Thus began their journey, initially supported by an EXIST research transfer grant, ultimately leading to the founding of the company.

After foundational research and a research stay in Belgium by Oliver Eckardt, Viktoria Rothleitner joined the team in 2017. With her Bachelor’s degree in Natural Sciences and currently studying for her Master’s in “Business Administration for Scientists,” she added essential business expertise. Together, in July 2017, the three founders successfully applied for EXIST funding, which kicked off the project in March 2018—initially still under the name “Hyperflow.”

Two years later, again in March, the official founding took place with the company’s registration in the commercial registry. During these two years, the team built a solid network, demonstrated proof-of-concept, established a scalable synthesis method, and further expanded the team. And although March 2020 also marked the start of something completely different, the team quickly adapted, successfully advancing their goals digitally and remotely.

 

The Journey Begins: From Project to Acceleration

The originally four-person team, with co-founder and scientific advisor Prof. Schacher remaining an integral part, not only relocated multiple times in the following years but also reached a series of significant milestones. These included continuous technological advancements, company growth, diversification of expertise within the team, multiple funding rounds, and prestigious awards — all leading up to the move into the future production facility in 2024.

Beyond these milestones, Polytives has showcased its technology at various trade fairs, including live demonstrations in Friedrichshafen, carried out extensive sample testing, and successfully scaled up production to an industrial level. Numerous strategic partnerships have also been established, including collaborations with institutions such as TITK e.V., as well as renowned distributors and mid-sized companies. Together, these partnerships drive continuous optimization and the implementation of projects that provide customers with an ever-expanding range of benefits.

 

What Lies Ahead?

While 5 years of Polytives GmbH signify a dynamic history filled with achieved milestones, these 5 years are truly just the beginning for the team. Plans are underway to establish in-house production facilities, complementing existing contract manufacturing partners and further accelerating product development to create even greater value for customers. Because that’s what drives Polytives: a unique platform technology capable of providing innovative solutions to numerous global challenges in the plastics industry.

And since space in a blog post is limited, we’ll just say for now: to be continued! 😉