Film and sheet recycling - the conditions and requirements ... · Washed PE film flakes PP film +...
Transcript of Film and sheet recycling - the conditions and requirements ... · Washed PE film flakes PP film +...
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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)
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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
• 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
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
• 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
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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
• 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
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
• 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
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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
• 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
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!