Manufacturer of lightweight polypropylene panels with its own value chain from recycling through extrusion to converting.
con-pearl GmbH
Geismar · Leinefelde-Worbis · Hillscheid · Greenville, SC (USA)New on Amplifa
System provider for PP lightweight panels and reusable solutions
con-pearl GmbH, headquartered in Geismar (Thuringia), is a manufacturer of lightweight polypropylene panels and a system provider for efficient reusable solutions with a return loop system (ECO-Loop). The entire value chain is mapped at the main plant: film production on extrusion and co-extrusion lines up to 2450 mm width, panel production on thermoforming-laminating lines, surface coating and finishing on embossing lines and bilaminate extruders, as well as converting into finished products through cutting, forming and joining processes on individual machines and highly automated lines. The Leinefelde-Worbis plant, a certified waste management specialist facility, handles recyclable material processing, compounding and granulate production in twin-screw extruders and operates its own materials laboratory with DSC analyses. At Hillscheid (acquired in 2021), PE and PP regranulates are produced, while at the US plant in Greenville, SC (Con Pearl North America Inc.) packaging rings are manufactured and panels are converted. Customer industries include logistics and warehousing, retail/POS, delivery, construction site protection, cargo area protection, automotive as well as interior fitting, furniture manufacturing, vehicle construction, shipbuilding and trade fair construction. The panels are made in part from post-industrial recyclates, are water-resistant and can be sawn, milled, drilled, laser-cut and thermoformed like wood; a fire-retardant version (con-pearl fire
- Site
- Geismar
- Processes
- Film production on extrusion and co-extrusion lines (up to 2450 mm width), Panel production on thermoforming-laminating lines, Surface coating and surface finishing on embossing lines and bilaminate extruders, Processing and converting of panel goods through cutting, forming and joining processes (individual, Processing options: sawing, milling, cutting, drilling, laser cutting, screwing, gluing, Recyclable material processing in shredding and pelletizing systems (sorting, fractionating,, Compounding and granulate production in twin-screw extruders (recyclate compounds with, Manufacture of packaging rings on an integrated production line with forming, punching and
- Materials
- Polypropylene (PP), Recycled PP (recyclates/post-industrial), Polyethylene (PE), Polypropylene, Recycled PP (Post-Industrial), Polyethylene, PP Recyclate Compounds, Co-extrusion
- Certificates
- ISO 9001:2015, ISO 50001:2018, ISO 14001:2015, IATF 16949, Certified waste management specialist facility, ISO 9001, ISO 14001, ISO 50001
- Industries
- Logistics/Warehousing, Retail/POS, Delivery/Last Mile, Construction Site Protection, Cargo Area Protection, Automotive
- 01
Take-back and purchase of PP residual materials and regrind
- 02
Recyclable material processing (shredding, sorting, pelletizing)
- 03
Compounding and granulate production
- 04
Materials laboratory and DSC analysis
- 05
Film extrusion and co-extrusion up to 2450 mm width
- 06
Panel production on thermoforming-laminating lines
- 07
Surface coating, embossing, bilaminate extrusion
- 08
Converting: cutting, forming, joining, punching, ultrasonic welding
- 09
Assembly into reusable solutions and industry systems
- 10
Return loop in the ECO-Loop
Materials and processes
Polypropylene
Base material of con-pearl lightweight panels, boards and multiboards for logistics, construction and interior fitting.
Recycled PP (Post-Industrial)
Own production residues and recyclates are used to manufacture the panels and fed back in the ECO-Loop.
Polyethylene
At the Hillscheid plant, mainly PE regranulates, alongside PP regranulates, are produced.
PP Recyclate Compounds
Compounds from defined PP material streams with application-specific additives, MFR 1-30, color-matched to RAL/Pantone.
Co-extrusion
Multilayer film construction up to 2450 mm width, from laboratory scale to series production.
Bilaminate Extrusion
Coating and surface finishing of the panels, e.g. with HPL wood-grain look.
Ultrasonic Welding and Punching
Joining and separating processes at the US location Greenville, since 2024 with a new ultrasonic welding/punching machine.
con-pearl fire retardant
Fire-retardant panel version for applications with increased fire protection requirements.
Locations
Geismar
DEMain plant: film production, panel production, surface coating, converting, sales
- Materials
- PP, recycled PP, bilaminate
- Extrusion and co-extrusion lines up to 2450 mm width
- Thermoforming-laminating lines
- Embossing lines
- Bilaminate extruders
- Cutting, forming and joining machines (individual machines and highly automated lines)
Leinefelde-Worbis
DEPlant: recyclable material processing, compounding, granulate production, materials laboratory, certified waste
- Materials
- PP, PE
- Shredding systems
- Pelletizing systems
- Twin-screw extruders
- Materials laboratory with DSC analysis
Hillscheid
DEPlant (formerly Recyplast GmbH, acquired 2021): production of regranulates from PE and PP
- Materials
- PE, PP
Greenville, SC
USPlant: packaging rings, panel converting, application engineering consulting (Con Pearl North America Inc.)
- Materials
- PP
- Integrated production line with forming, punching and joining machines
- Ultrasonic welding/punching machine (since 2024)
- Cutting and joining machines for panel converting
Components and products
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Film production on extrusion and co-extrusion lines (up to 2450 mm width)Plastics | – | 2450 mm (film width) | – | – | PP (polypropylene) |
| Panel production on thermoforming-laminating linesPlastics | – | – | – | – | PP (polypropylene) |
| Surface coating and surface finishing on embossing lines and bilaminate extrudersSurface | – | – | – | – | PP (polypropylene) |
| Processing and converting of panel goods through cutting, forming and joining processes (individualPlastics | – | – | – | – | PP (polypropylene) |
| Processing options: sawing, milling, cutting, drilling, laser cutting, screwing, gluingPlastics | – | – | – | – | PP (polypropylene) |
| Recyclable material processing in shredding and pelletizing systems (sorting, fractionating,Plastics | – | – | – | – | PP (polypropylene), PE (polyethylene) |
| Compounding and granulate production in twin-screw extruders (recyclate compounds withPlastics | – | – | – | – | PP (polypropylene) |
| Manufacture of packaging rings on an integrated production line with forming, punching andPlastics | – | – | – | – | PP (polypropylene) |
| Regranulate production (regranulates mainly from polyethylene, but also polypropylene)Plastics | – | – | – | – | PE (polyethylene), PP (polypropylene) |
| Ultrasonic welding and punching (ultrasonic welding/punching machine, Greenville USA)Joining | – | – | – | – | PP (polypropylene) |
10 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Extrusion and co-extrusion lines (film production) | – | – | up to 2450 mm film width | – | Geismar |
| Thermoforming-laminating lines (panel production) | – | – | – | – | Geismar |
| Embossing lines (surface finishing) | – | – | – | – | Geismar |
| Bilaminate extruders | – | – | – | – | Geismar |
| Cutting, forming and joining machines (individual machines and highly automated production lines) | – | – | – | – | Geismar |
| Shredding systems | – | – | – | – | Leinefelde |
| Pelletizing systems | – | – | – | – | Leinefelde |
| Twin-screw extruders (compounding/granulate production) | – | – | – | – | Leinefelde |
| Integrated production line with forming, punching and joining machines (packaging rings) | – | – | – | – | Greenville, SC (USA) |
| Ultrasonic welding/punching machine | – | – | – | 2024/2025 | Greenville, SC (USA) |
Additional services
Reference customers
Quality and certifications
con-pearl GmbH operates with an integrated management system: ISO 9001 and IATF 16949 (Geismar), ISO 14001 at both German panel locations, ISO 50001 for energy management, as well as certified waste management specialist facility in Leinefelde. Raw materials and finished granulates are tested in the company's own materials laboratory, among other things by DSC analysis.
| Evidence | Geismar | Leinefelde-Worbis |
|---|---|---|
| ISO 9001 | ||
| ISO 14001 | ||
| ISO 50001 | ||
| IATF 16949 | ||
| Certified waste management specialist facility |
History
- 2003
Initial ISO 14001 certification for the Geismar site
- 2016
Initial ISO 50001 certification (Geismar, Leinefelde) and ISO 14001 (Leinefelde)
- 2018
IATF 16949 certification for the Geismar and Bremen sites (friedola TECH)
- 2019
Successful trade fair appearance at LogiMAT Stuttgart with 120 new contacts
- 2021
Acquisition of Recyplast GmbH in Hillscheid (April 2021) to secure raw material supply
- 2024
New ultrasonic welding/punching machine at the US plant in Greenville
- 2026
Florian Kisling takes over as Managing Director effective August 1; first trade fair appearance at EMPACK Ghent