Resource constraints, regulatory pressure and evolving end user expectations are accelerating material and process changes across the plastics value chain. Leonhard Kurz plans to use K 2025, the international trade fair for the plastics industry taking place in Düsseldorf from October 8 to 15, to detail how several of its developments address recyclability, emissions and energy efficiency without departing from established quality and functional benchmarks. The company will highlight three main strands. First, natural fiber polypropylene composites, referred to as NFPP, intended for lightweight structural and decorative components. Second, Recosys, a take-back and recycling system that supplies single-type rPET granulate for use in automotive interior textiles. Third, EcoLayer FX, a surface decoration approach compatible with polypropylene-based substrates with natural fillers. Demonstrations are planned with technology and material partners to show series-feasible processing routes, including large-area finishing, integrated back injection and textile conversion, as well as a closed-loop rPET showcase within the VDMA special show.
Natural fiber polypropylene composites (NFPP)
NFPP combines polypropylene with natural fibers such as flax or kenaf to achieve weight savings of up to 40 percent versus conventional plastic solutions, while maintaining stability and good formability. The material also provides sound and heat insulation effects and a visibly organic surface. Manufacturing is designed for series production: under heat and pressure, a natural fiber mat coated with PP fibers is bonded to a decorative substrate to form a robust, recyclable component.
At K 2025, Kurz, together with Polyvlies and Frimo Innovative Technologies, will present three NFPP applications. A decorated door element approximately 80 centimeters wide illustrates high-quality, efficient large-area finishing with the DecoPress process. The natural fiber mat in this exhibit consists of equal parts recycled natural fiber and recycled polypropylene. A second interior component uses a mat containing recycled NFPP elements, yielding a material mix with a high-quality appearance and increased recycled content. As a third example, a cover component will be manufactured live at the stand of partner company Wittmann. In this case, the natural fiber structure is decorated on the front and back-injected on the rear in one integrated sequence to meet visual and structural requirements.
K2025 Natural Fiber Reinforced Polypropylene
Recosys rPET and textile applications
Recosys is Kurz's take-back and recycling system aimed at closing the material loop and supplying high-quality, single-type rPET granulate. At K 2025, in cooperation with Farplas, Topp Textil and Technofibres, the company will show how this rPET can be processed into technical textiles for automotive interiors. The resulting textile surfaces are designed to align with vehicle interior requirements in structure, haptics and appearance while improving the environmental balance.
The rPET granulate is intended for applications such as seat covers, door panels and trim moldings. According to Kurz, this supports OEMs in implementing sustainable design approaches with high technical performance and in meeting the requirements of the EU Recycling Directive for new vehicles. The first textiles produced are described as resource-efficient and indicate the current development status of recycled PET. Additional details will be presented as part of the VDMA special show "The Power of Plastics", where Kurz plans to display a closed cycle from raw material to finished demonstrator.
EcoLayer FX on PP substrates with natural fillers
EcoLayer FX enables high-quality decoration on substrates that combine natural materials with polypropylene, for example talc with PP, PP with cellulose content or limestone with PP. The decorative layer is thinner than a human hair and, according to the company, does not affect the recyclability of the decorated part. This allows visually differentiated designs on hybrid PP substrates without compromising processability.
At the fair, Kurz will display various EcoLayer FX designs to illustrate the use of polypropylene with natural additives in industrial practice, giving OEMs and processors additional options for functional and brand-defining surfaces at a technical level comparable to conventional plastic solutions.
K2025 EcoLayerFX
Exhibit focus and presence at K 2025
The exhibits concentrate on combining resource conservation, material efficiency and industrial design within scalable processes. They include the use of recycled inputs, bio-based material additives and integrated processing steps such as back injection and large-area finishing.
At a glance
- K 2025, October 8 to 15, Düsseldorf
- Leonhard Kurz Stiftung & Co. KG: Hall 5, Booth A19
- Focus: exterior design, interior design, sustainability
