Symposium

1
Symposium REPLAST 2008 L.Padanyi
Balatonfüred 24./25. Jan. 08
EREMA Plastic Recycling Systems
Technology
2
Actual company data

• Founded 1983
• Managing directors
  2
• Klaus Feichtinger, Manfred Hackl, Gerhard
  Wendelin
• Employees in Ansfelden 270, worldwide 320
• Turnover over 100 million in 2007
• ? 40 agencies worldwide
• Export quote 97-99 , out of this 50 EU, 25
  North and South America, 25 Near and Far East

3
Headquarter in Austria
4
Subsidiaries

• Austria (Roitham)
  4
• manufacturing of screws, screen changer parts
• EREMA North America (Ipswich)
• Sales and service for USA and Canada
• EREMA China (Shanghai)
• Sales, service and spares
• EREMA Japan (Yokohama)
• Sales, service and spares

5
References

• more than 3.000 delivered recycling systems 5
  throughout the world for
• PE
• PP
• PA
• PS
• PC
• PET
• more than 2.900 melt filter references

6
Product range complete lines 6

• EREMA PC Classic System
• KAG continous agglomerator
• COAX single shaft shredder combined with
  extruder
• VACUREMA PET recycling solutions
• SCREEN CHANGERS RTF automatic backflush
• LASERFILTER high performance filter systems
• PELLETISING SYSTEMS hot die face / strand
• SCREWS CYLINDERS made by 3S

7
EREMA PC 7

• output rates from 100 kg/h 2.700 kg/h

• T (without degassing)
• TE (with double venting)
• TVE (with double venting
• after screen changer)

EREMA 1514 TVE-DD
8
EREMA PC - options 8

• material thermoplastics
• physical form
• film rolls via reel feeder
• precut film
• chad
• edge trims
• preground material
• preforms
• non-woven
• tapes, fibre etc.

9
History

• easy process 9
• no two- or three-step process necessary

• Generation radial arrangement of extruder to
  cutter-compactor

• improved feeding of the extruder
• higher output

• Generation tangential arrangement of extruder to
  cutter-compactor

• improved mixing within cutter-compactor
• higher output

• Generation the improved recycling solution with
  enlarged cutter-compactor

10
EREMA PC-function of cutter compactor 10

• cutting and feeding
• heating through friction
• drying
• densifying
• dosing e.g. CaCO3

11
EREMA PC - function of extruder 11

• complete melting
• plasticising
• homogenising

12
EREMA PC liquid cooled extruder

• exact control of extruder heating zones
  12
• production independent from ambient temperature
• no dust emmissions
• no sound emmissions

13
EREMA PC type T - schema 13

• for processing of unprinted material

input waste
cutter compactor
melt filter
extruder
main drives
14
EREMA PC type TE schema 14

• for processing printed material

double venting
input waste
cutter compactor
melt filter
extruder
main drives
15
EREMA PC type TVE schema 15

• for processing of heavily printed materials

with double venting after screen changer
cutter compactor
input waste
main drives
melt filter
extruder
16
VORTEILE TVE versus TE 16

• TVE der Dreck wird herausgefiltert und eventuell
  verbleibende Restfeuchte, sowie Gase von der
  Bedruckung werden danach vollständig bei der
  darauffolgenden Entgasung entfernt.
•  
• TE das Material wird Entgast, aber der Schmutz
  ist noch im Material und neigt dazu (bis zur
  Filtration am Ende des Extruders) in Kombination
  mit Restfeuchte weitere Gase aufzubauen. Bei der
  Filtration wird der Dreck zwar herausgefiltert
  aber der vorhandene Restgasgehalt bleibt in der
  Schmelze und wird im Granulat eingeschlossen.
•  

17
EREMA Double Disc technology schema 17
second disc -gt Double Disc
18
EREMA Double Disc technology 18

• EREMA 3rd Generation
• large diameter drum
• additional disk above the
• conventional one
• ? efficient drying of film flakes
• up to 8 humidity, by
• devided disc functions and
• complementary measurements

19
TVE Type Extruder
19
20
TVE System with Pellet-Water separation
screen
20
21
KAG continous agglomerator 21

• output range from 10 kg/h 200 kg/h

KAG 504
KAG 806
22
KAG options
22

• Edge trim cyclone
• automatic inline processing of edge trims
• Reel feeder device - film from rolls
• Conveyor belt
• Mainly LDPE, LLDPE, HDPE and PVC
• Final product air cooled pellet
• Three sizes 10-40 30-100 100-200 kg/h

23
KAG - die face design 23

• NEW
• improved
• design!

24
Continuous Agglomerator KAG 806 with Reel 24
Feeder air cooled Hot Die Face Cutting system
25
COAX
25

• output range from 100 kg/h 500 kg/h

COAX 301 E
26
COAX - technique 26

• cutting tool and extruder mounted on one shaft
• load balancing with two pushers
• low degradation
• no precutting problems
• no intake problems

27
COAX - options 27

• input material
• LDPE, LLDPE, HDPE
• PP, BOPP
• PS, XPS, HIPS, ABS
• PA6.0, PA6.6, BOPA,
• physical form
• bulky material
• rafia
• big bags
• cords
• etc.

28
COAX - schema
28

• output range from 100 kg/h 500 kg/h

• feeding hopper
• Single-shaft-shredder
• main drive
• segment pusher system
• single screw extruder
• double venting
• melt filter

4
1
6
7
2
3
5
29
VACUREMA PET recycling solutions 29

• output ranges up to 2.500 kg/h

KT
Reactor
VACUREMA 1716 T-VS
30
PET Recycling steps 30

• collecting
• sorting
• washing / grinding / drying
• predrying/decontaminating
• extrusion
• pelletising or inline appl.
• crystallisation
• IV increase

done by EREMA with VACUREMA
31
VACUREMA - PET options inline 31

• fibre or filaments
• thermoforming sheet
• packaging sheet
• strapping band
• non-woven

32
High IV increase big flake surface 32

• ? Bottle-flakes preground
• with a 12 mm screen
• average wall thickness
• 0,1 0,4 mm

• Pellets typical dimensions
• 2,5 mm diameter x 3 mm length

33
VACUREMA - different technology for different IV
33

• VACUREMA BASIC

? VACUREMA ADVANCED ? VACUREMA PRIME
34
VACUREMA BASIC 34

• ? Patented combination of vacuum reactor and
  single-screw extruder
• FDA approved, ILSI compliant, BTB-compatible
  system for market entry
• ? Producing ultra fine-filtered repellets at
  lowest possible investment and
• operating cost
• ? IV-loss of 3-5 can be adjusted within limits
  (to max. 0) via throughput

35
VACUREMA ADVANCED 35

• ? First expansion stage of the Vacurema Basic
  technology
• ? Equiped with a vacuum crystallisation dryer it
  provides additional
• pre-drying and decontamination of the input
  material
• ? In the process from flake to repellets
  depending on input flake quality thismakes an IV
  increase of 2-6 possible
• ? The Vacurema Advanced BTB-system has many
  individual country
• approvals

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VACUREMA 1716 T with Automatic strand pelletizing
and Inline crystallisation 36
37
VACUREMA PRIME 37

• ? Building on Vacurema Basic and Vacurema
  Advanced systems,
• this high-end extrusion system features two
  vacuum crystallisation
• dryers operating in batch mode enabling an
  exceptionally high level
• of purity with an IV increase of 8-10
• ? The technology is FDA C certified, i.e.
  universally applicable without
• restriction for the reprocessing of PET
  material flows coming from
• - Deposit (returnable) systems
• - Mixed household (curbside) collections, resp.
• - Non-food packaging (e.g. shampoo bottles,
  etc.)

38
VACUREMA - Multi KT System 38
input material
input material
vacuum sluice
vacuum sluice
vacuum pump
Multi KT System Feeding and processing steps are
alternating
vacuum pump
vacuum sluice
melt filter
Continuous working VACUREMA reactor/extruder
combination
reactor
extruder
granulation
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VACUREMA - input and output BTB 39

• input
• washed flakes

• output
• crystallised pellets

with available inline crystallisation equipment
from EREMA
40
VACUREMA - inline-crystallisation 40
strand die
crystallisation table
granulator
conveying blower
pellet separating
centrifuge
water slide
classification screen
41
VACUREMA - advantages BTB 41

• unique cleaning effect before material is molten
• proved for direct food contact
• IV increase without solid state reactor and
  without external predrying and crystallising
• melt filtration fineness up to 32 µm
• simple continous process

42
VACUREMA - advantages costs 42

• lower energy costs appr. only 0,3 kW/kg
• lower production costs appr. 10 cent/kg
• space saving design e.g. appr. 300 m2 for a
  plant with 1.000 kg/h output capacity
• flexible and upgradeable system

43
VACUREMA - references 43

• more than 100 VACUREMA PET recycling plants
• 50 for Bottle-to-Bottle
• more than 25 plants for inline applications
• approx. 200.000 t/year of food grade PET
• all VACUREMA plants are producing globally about
  400.000 t/year

44
EREMA melt filters 44

• with patented backflush technology

SW 4/82
SW 12/170
45
EREMA melt filters operational principles

• hydraulic operated pistons
  45
• round screens (mesh)
• automatic backflush without interrupting the melt
  flow
• twin- or four-piston design allows screen change
  without stopping the extrusion process

46
EREMA melt filters automatic backflushsequence
46
piston 1 and 2 in production position all 4
screen packs in active filtration position
2
melt inlet
main melt flow
I
II
1
47
EREMA melt filters automatic backflushsequence
47
cleaning of screen pack I in piston 1 piston 1 in
backflush position 1
2
melt inlet
main melt flow
II
I
1
backflush melt flow
48
EREMA melt filters automatic backflush
sequence
48
cleaning of screen pack II in piston 1 piston 1
in backflush position 2
2
melt inlet
main melt flow
I
II
backflush melt flow
1
49
EREMA melt filters automatic backflushsequence
finished 49
piston 1 and 2 in production position all 4
screen packs in active filtration position
2
melt inlet
main melt flow
I
II
1
50
EREMA melt filters screen changing 50
piston 1 in sreen change position piston 2 covers
100 production
2
melt inlet
main melt flow
I
II
1
51
EREMA Laserfilter
51

• extreme separating of soft impurities

LF 2/350
52
EREMA Laserfilter overview 52

• efficient continous filtering of soft
  contamination eg. paper, aluminium, wood, copper
  etc.
• fully automatic constant pressure operation
• 600-1000 hours screen change interval
• minimum melt loss
• filtration fineness 11020 µm up to 23030 µm
• throughput capacity 250 1.200 kg/h

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EREMA Laserfilter schema 53
54
4th generation HG downstream 54
55
Die face for PP 55
56
EREMA Double Disc technology advantages
56

• decoupling of two process steps
• step 1 material preparation
• step 2 feeding of extruder
• keeping away negative influence on feeding
• higher moisture content possible
• constant running extruder
• 15 more output
• available for all EREMA PC systems (T, TE, TVE)

57
EREMA - Advantages 57
EXPERIENCE

• Nr. 1 supplier for single screw recycling
  solutions

• performance test at EREMA before shipment of the
  plant to the customer shows reliable quality

QUALITY

• lab with 5 full-size plants, high and steady
  investments into R D

INNOVATION

• large service department, spare parts stock,
  worldwide 24-hour-customer service network

SERVICE
58
Schnecken Spindeln Spiralen 58

• manufacturing of screws and cylinders
• single screws
• twin screws
• screw elements
• cylinders
• Einzugsbuchsen/Nutenbuchsen
• regeneration
• of screws and cylinders

59
Thank you

• EREMA Engineering Recycling
• Maschinen und Anlagen Ges.m.b.H.
• A-4052 Ansfelden / LINZAUSTRIA
• Phone  [phone]
• Fax  [phone]
• Email  erema_at_erema.atwww.erema.at

Technical executions subject to change. EREMA
reserves modifications without prior notice.