Depending on the physical form of the material, any recycling line can be equipped with an edge trim cyclone (for inline operation), reel feeder (for films on rolls), or a feeding conveyor (for loose material, bales, flakes).
Dosing and compounding
Due to our commitment to continuous technological progress, the recoSTAR product range has been extended to integrate compounding into the recycling process. By means of exact dosing of various additives in liquid, pellet, or powder form, the properties of the regranulate may be adjusted to meet the requirements of the final application.
Regardless of the pre-treatment process, the plastic is being compacted and molten by means of a single screw extruder; our unique screw design results in excellent product quality. Optionally, every extruder may be equipped with a vacuum unit, a double-vacuum unit, a high-vacuum unit, or a C-VAC module. Through the use of vacuum, loss of viscosity is reduced, and volatile contamination and monomeres are extracted.
Solid foreign particles are being extracted by means of a melt filter. With regard to filtration, our customers may choose between the following filtration systems: discontinuous, continuous, and continuous with a high-capacity backflushing mode (power-backflush). The continuous filter consists of a double piston, whereby each piston is equipped with a filter unit. In relation to extruder size, each filter unit is large enough to filter 100% of the melt during backflushing or filter change. The main advantage of this design is a melt flow that is free of deflection and dead corners. Otherwise, the material would start to accumulate and degrade, and in case of it being carried along, it would contaminate the purified melt flow. For higher levels of contamination, we recommend our power-backflushing filter, or alternatively our continuous rotation filter.
Depending on the application, one of three pelletising systems is selected:
- Water ring pelletising
- (Automatic) Strand pelletising
- Underwater pelletising
Our patented waterring pelletiser ensures the optimal cutting of the polymer melt which is pressed through a vertically perforated plate. The centrifugal force transports the granulate into the process water of the drum. After its separation from the water, the lense-shaped granulate is dried gently in a centrifuge.
By means of the conventional strand pelletising, the polymer strands are led through a water bath, and after cooling, the strands are cut to cylindrical granulate. The automatic strand pelletising is particularly user-friendly and allows for high availability of the recycling line.
The advantages of the underwater pelletiser are easy start-up, fully automatic operation, minimal need for operating personnel, economical use of floor space, and reduced consumption of cooling water. The process water flushes the die plate as well as the knife head; the granulate’s form is spherical. Optionally, an inline crystallisation may be installed in order to produce granulate with a high level of crystallinity.
Energy efficiency and alternative energy
rECO is an innovative approach that improves the energy efficiency of the recycling line. The overall energy consumption kW/kg is reduced by approx. 10 %. Benefit for the client is reduced costs, benefit for the environment is reduced carbon footprint.
The rECO package includes amongst others:
- New drive concept for the main drive of the extruder
- Main motors in IE3 standard resp. NEMA Premium, the most energy efficient motors available.
- Barrel heating is done with infrared heaters.
- Energy recovery solutions are optionally available for various process steps.
recoSTAR lines can alternatively use natural gas or steam as a heating medium.