Film and sheet recycling - the conditions and requirements ... · Washed PE film flakes PP film + paper contamination • Mixed plastics, washed film flakes, multilayer film need

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Film and sheet recycling -

the conditions and requirements for a recycling

plant manufacturer

DI(FH) Andreas Rößler-Czermak, R&D Engineer

e-mail: [email protected]

4. + 5. Juni OCS Witten (Germany)

mailto:[email protected]

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Overview

• Global trends and recycling market overview

• EREMA company profile

• EREMA technologies for film recycling

• The challenge of film recycling

• From a pellet quality to a product quality

• Conclusions

Plastics market overviewWorld thermoplastic consumption

Source: EREMA market data base

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Plastics market overviewRecovery in europe 2012

47 Mio tConverter demand

Consumer demand

+ Import

- Export

+ Import

- Export

25 Mio t post consumer

waste

10.2 Mio t Disposal

8.6 Mio t Energy

recovery

6.3 Mio t Recycling

production waste recyclingSource: plasticseurope

“Urban Mining”

Consumer demand

European Waste Framework Directive (2008/98/EC)

Oil price

Worldwide TREND towardssustainability, recycling, energy-efficiency

Political strategies

Media “hot topic”

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Overview






• Conclusions

EREMA GroupHard Facts• 1983 founded with the idea of “Plastics Recycling”

• Turnover EREMA Group

• Fiscal year 2012/13 over 117 mio €• Fiscal year 2011/12 over 127 mio €• Fiscal year 2010/11 over 95 mio €• Fiscal year 2009/10 over 74 mio €

• Approx. 250 recycling plants a year

• 100 % privately owned and independent company

• More than 400 employees worldwide

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EREMA GroupHeadquarters, Austria

EREMA HEADQUARTERSEREMA HEADQUARTERS EREMA CUSTOMER CENTREEREMA CUSTOMER CENTRE

PRODUCTION HALLPRODUCTION HALL INCOMING Q-CONTROLINCOMING Q-CONTROL R&D CENTRER&D CENTRE

EREMA Group@ work

No. 1EREMA is the Number One in the global market

93Employees have worked for EREMA at the headquarters for more than 10 years

4,000Over 4,000 EREMA systems in use worldwide

5EREMA is represented in all 5 continents

400 Employees producing 250 systems yearly 100,000

Parts available in the company's own high-bay warehouse

20Tonnes of steel processed every day

400Technical trials and experiments for customers per year 12 mill.

Tonnes of secondary raw material produced annually using EREMA systems

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Plastic recycling systemsEREMA Products

HIGH TECH PLASTICRECYCLING

EREMA T, TE und T/HP

FIBRE AND TAPE RECYCLING

COAX

HIGH-CAPACITY MELT FILTRATION

MELT FILTERS

EDGE TRIM RECYCLING

KAG

PET Recycling Systems

VACUREMA

PELLETISING SOLUTIONS

HG D

PET PREDRYING AND CRYSTALLISING

MPR – Multi Purpose Reactor

LASER FILTERS ASP-CIC

HIGH PERFORMANCE DEGASSING

TVEplus

Overview






• Conclusions

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EREMA plastic recycling systemsApplications

For all thermoplastic polymers (e.q. PE, PP, PET, PS, ABS, PA, PC, biopolymers, compounds…)

and different plastic form(e.q. film, hollow body/bottle, foam, fibre, tape…)

• In-house production waste recycling

• Post-industrial waste recycling

• Post-consumer waste recycling

• Food contact approved PET recycling

EREMA T, TE, TVEplusCharacteristics

• EREMA cutter compactor

+ tangential arranged single screw extruder

> without degassing – T-type> with degassing – TE-type

• Excellent material preparation ensured by large EREMA cutter compactor

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storage

force feeding

cutting

homogenisation

preheating

gas removal densification

Several functions in one stepThe EREMA cutter compactor

• Extruder is fed with preheated

and

homogenous material(temperature, bulk density, humidity size etc.)

• No air inclusions in the melt

• Melting with MINIMUM shearing

impact

PE, PP film (printed)PE, PP film (printed)PE film (non-printed)PE film (non-printed)

Film & sheet recycling – INHOUSE & INDUSTRIAL waste

LDPE edge trimLDPE edge trim LLDPE stretchfilmLLDPE stretchfilmHeavily printed PE,PP filmHeavily printed PE,PP film

• Bulk density - deal with different shapes and sizes• Cleanness - input material without contamination - need to be

kept clean• 100% re-use - gentle recycling without degradation (short heat

history, no oxidation)• Homogeneous pellet shape for proper re-use

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Film & sheet recycling – INHOUSE & INDUSTRIAL waste

• Specially for inhouse applications:• Storage – clean and short• Flexible output rates• Fully automatic controlled – self adjusting• Compact plant dimensions

EREMA T and TE KAG TVEplus

PP film + paper contaminationPP film + paper contaminationWashed PE film flakesWashed PE film flakes

• Mixed plastics, washed film flakes, multilayer film need homogenisation• Need for filtration capacity on a high level (e.q. sand, dust, aluminium,

wood, paper) • Drying before the extrusion process• High Output• Degassing AFTER melt filtration to enhance degassing performance

Film & sheet recycling – POSTCONSUMER waste

TVEplus

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Overview






• Conclusions

The challenge of (film) recycling:

A nice looking pellet is NOT enough!

• Continously further developed plastics

• New plastic compounds and products as ingoing material

• Most of the time no data sheet

• Continously increasing quality requirements

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Examples:

• In the past for food packaging there were mono films or films with 2 layers.

Today: a film with 7 layers with barrier-, carrying- and oxidizing layers.

• Dosing of metallocene: if it is not perfect or changed intentionally, the

characteristics of the polymer changes. Not only the mechanical and

rheological properties, also the processing changes.

• PET bowls for food, e.g. salad, pizza, cheese etc. is coming

more and more, low IV (bottles to sheet), food contact.

The real polymer quality can often ONLY be seen in the film

Overview






• Conclusions

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From a pellet quality to a product quality

Customer needs proved product quality

OCS Blown and Cast Film line with film inspectionLight microscope Dry air dryer

Targets with the OCS film line

• Case by case for and with our customers:

• Comparison of gels between different filtersystems

• Illustration of the distribution of compoundings (Corema)

• Detection of gas inclusions70%LDPE, 30%CaCO3

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Targets with the OCS film line • Comparison of components and recycling

systems for R&D:

• degassing systems and degassing efficiency

• Filter systems and filter efficiency

• Screw types and design

• Evaluation of r-pellet quality and complete recycling processes

Erema as a COMPETENT partner for film and sheetquality intensification

Further steps

• development of further know how of defect characteristics

• Creation of internal working guidelines

• Creation of internal standards for defect analysis

• Acquirement of knowledge of virgin material

Erema with OUTSTANDING technology for the completefilm and sheet recycling and reuse process

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Acquirement of knowledge of virgin material –what does that mean?

• Recycling is a daily business and omnipresent

• Recycling rates are strongly increasing

• Virgin material supplier and EREMA have often the same concern:

satisfying the same customer!

• As more as we know from your material as better we can satisfy

our common customer!

Acquirement of knowledge of virgin material: example

• Project together with OEM

• We have to have the knowledge about the complete processing

before, at and after the machine and

• about the in and out going material quality

• With the full understanding problems can be solved or avoided

dust fibre crystal

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Overview






• Conclusions

We close the loop…

• ….by having the focus on the APPLICATION and the NEEDS of our customers

• ….by supporting our customers with KNOW HOW not only related to the Erema

machine

• ….by beeing the EXPERT both film recycling and conventional polymer recycling

• ….by having the complete KNOWLEDGE both PROCESSING and MATERIAL

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Linz, AUSTRIA

GLOBAL HEADQUARTERS. PRODUCTION FACILITIES.EREMA Customer Centre. R&D Centre.

Thank you!

Documents

Film and sheet recycling - the conditions and requirements ... · Washed PE film flakes PP film + paper contamination • Mixed plastics, washed film flakes, multilayer film need