Digitalization techniques in polymer processing – a review

doi:10.1515/ipp-2025-0053

Study

Commercial ProductionNew This WeekStrong effect

Digital Twins in Polymer Processing Boost Efficiency and Sustainability

Implementing digital twins in polymer processing can lead to more efficient, resilient, and sustainable manufacturing practices by enabling holistic optimization.

International Polymer Processing · 2025

01

Key Findings

01Digitalization offers significant opportunities for improving the plastics industry.
02Current applications of digitalization in polymer processing demonstrate benefits but often lack scalability, adaptability, and generalizability.
03There is ample room for further research and development to achieve advancements beyond current state-of-the-art methods.

02

Application

Design takeaway

Embrace digital twin technology and smart factory principles to create more efficient, resilient, and sustainable polymer processing operations, while actively seeking to improve the adaptability and scalability of these solutions.

How to apply

Investigate and implement digital twin strategies for polymer processing lines, focusing on creating interconnected systems that allow for real-time monitoring, simulation, and optimization.

Project actions

01When researching digital twins, consider the specific polymer processing application and how a digital twin could address its unique challenges.
02Evaluate the potential for scalability and adaptability of any proposed digital twin solution.

03

Method & Evidence

AimWhat are the current levels of digitalization in polymer processing, and what are their benefits and limitations?

MethodLiterature Review

ProcedureThe paper reviews existing methods and case studies in the digitalization of the plastics processing industry, classifying them into four levels: offline modeling, digital shadows, digital twins, and smart factories. It examines the underlying technologies and their applications.

ContextPolymer processing industry

Variables

IVLevels of digitalization (offline modeling, digital shadows, digital twins, smart factories)

DVEfficiency, resilience, sustainability of manufacturing practices

CVSpecific polymer processing techniques, types of sensors, control systems

04

Strengths & Limitations

Strengths

+Provides a comprehensive overview of digitalization in polymer processing.
+Classifies digitalization into distinct, understandable levels.
+Includes case studies to illustrate applications.

Limitations

The review is a broad overview, and specific technical details for implementing digital twins in niche polymer processing applications might require further specialized research.

Reliability & validity

The reliability of this review's findings is based on the synthesis of multiple studies and case examples within the field of polymer processing digitalization. Validity is supported by the classification of technologies and the discussion of both benefits and limitations.

Think critically

To what extent can current digital twin technology be generalized across the diverse range of polymer processing techniques, and what are the primary barriers to achieving this generalization?

05

Design Principles

"Leverage digital twin technology for holistic process optimization in manufacturing."

The integration of digital technologies, from offline modeling to fully interconnected smart factories, offers significant opportunities to enhance the plastics industry. While current applications demonstrate benefits, there is substantial room for research and development to improve scalability, adaptability, and generalizability.

06

What This Means for Your Design

Using computer models that act like a real machine (digital twins) can help make plastic manufacturing better, more efficient, and more environmentally friendly, but these models need to be made more flexible and widely applicable.

How to use in your project

1.Reference this review when discussing the benefits and challenges of implementing advanced digital technologies like digital twins in a design project's manufacturing phase.
2.Use the identified levels of digitalization to structure a discussion on the evolution of digital manufacturing in your chosen context.

07

Add to My Project

08

Quick Cite

(2025). Digitalization techniques in polymer processing – a review. International Polymer Processing. https://doi.org/10.1515/ipp-2025-0053 Retrieved from https://designdex.org/study/b512f6dd-ac18-49af-b79d-8d923b69814e/digital-twins-in-polymer-processing-boost-efficiency-and-sustainability

Paragraph starter

This review highlights that advanced digital technologies, particularly digital twins, are transforming polymer processing towards greater efficiency, resilience, and sustainability. While current applications demonstrate clear benefits, the research indicates a need for improved scalability and adaptability to fully realize the potential of these technologies in creating optimized smart factories.

09

Source

International Polymer Processing

Digitalization techniques in polymer processing – a review

journal · 2025

View source

Questions about this research

What does the research say about digital twins in polymer processing boost efficiency and sustainability?: Embrace digital twin technology and smart factory principles to create more efficient, resilient, and sustainable polymer processing operations, while actively seeking to improve the adaptability and scalability of these solutions. Evidence: International Polymer Processing (2025).
Why does "Digital Twins in Polymer Processing Boost Efficiency and Sustainability" matter for design?: The integration of digital technologies, from offline modeling to fully interconnected smart factories, offers significant opportunities to enhance the plastics industry. While current applications demonstrate benefits, there is substantial room for research and development to improve scalability, adaptability, and generalizability.
How can designers apply this research?: Embrace digital twin technology and smart factory principles to create more efficient, resilient, and sustainable polymer processing operations, while actively seeking to improve the adaptability and scalability of these solutions.
What were the main findings?: Digitalization offers significant opportunities for improving the plastics industry.. Current applications of digitalization in polymer processing demonstrate benefits but often lack scalability, adaptability, and generalizability.. There is ample room for further research and development to achieve advancements beyond current state-of-the-art methods.
What research method was used?: Literature Review.
How strong is the evidence?: Evidence strength is rated Strong effect, based on a 2025 journal from International Polymer Processing.
What should I do differently in my next project?: Investigate and implement digital twin strategies for polymer processing lines, focusing on creating interconnected systems that allow for real-time monitoring, simulation, and optimization.
What are the limitations?: The review highlights that current digital twin applications in polymer processing are often lacking in scalability and generalizability, and there are still areas where digitalization has not been demonstrated.
Is there evidence that polymer processing affects design outcomes?: Digitalization, including digital twins, can significantly improve polymer processing efficiency and sustainability, though current implementations need further development in terms of scalability and adaptability. The integration of digital technologies, from offline modeling to fully interconnected smart factories, o Source: International Polymer Processing (2025).
Where does this digital twins research apply?: Polymer processing industry It sits within commercial production research on designdex.org.