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Innovative Degassing and Decontamination Technologies for Demanding Recycling Applications

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Innovative Degassing and Decontamination Technologies for Demanding Recycling Applications

Gneuss Extrusion Technology

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New OMNI Recycling Machines for closed loop recycling of PET, PS and polyolefin post-consumer reclaim

Gneuss’ MRS Extrusion Technology has proven itself as an alternative for the reprocessing of contaminated materials like polyester, polystyrene, polypropylene or polyethylenes. In combination with the highly efficient Gneuss Rotary Filtration Systems and optimized vacuum technology, customizable recycling lines tailor-made for a specific material can be engineered. Several Letters of Non Objection (LNOs) from the FDA, EFSA conformity and local approvals in Latin America confirm the decontamination efficiency of the technology.

OMNI Recycling Machine for post-consumer fiber or thermoform reclaim

Gneuss will show its latest machinery innovations for today’s and tomorrow’s recycling needs with the new OMNI Recycling Machines.

The OMNImax Recycling Machine processes industrial and post-consumer waste from all kinds of polymers and in all forms and shapes. It includes a 3C Rotary Feeder, an
MRSjump extruder, a fully automatic melt filtration system RSFgenius and an online viscometer VIS.

3C Rotary Feeder

The newly developed 3C Rotary Feeder makes it possible to use low bulk density materials without any external processing steps. A conveyor belt feeds shredded reclaim material into the hopper, where a fast-rotating disc with knives cuts, compacts and pre-conditions the material. The knives add energy into the material and start the heating and degassing process before the material is automatically fed into the MRSjump extruder.

MRSjump

The MRS extruder is based on conventional single screw technology but is equipped with a multiple screw section for devolatilization. It enables very efficient and gentle decontamination of PET, whilst achieving the requirements for direct food contact standards. The MRS extruder permits the processing of R-PET directly into high quality end products such as packaging sheet, strapping tape or filaments without pre-drying by using a simple and rugged vacuum system. This is achieved by means of its unique and patented processing section. The Multi Rotation Section is a drum containing multiple satellite single screws, driven by a ring gear and pinion transmission.

The satellite screws rotate in the opposite direction to the main screw. This disproportionately increases the surface exchange of the polymer melt. A large opening for venting, exposing the full length of the satellite screws, is completely under vacuum. This provides excellent and unrestricted access to the polymer melt, the surface of which is constantly replaced at an extremely high rate by the action of the satellite screws in the multiple screw section. The surface area – and the surface area exchange rate – available for devolatilization are far greater than in other extrusion systems. As the thermal and mechanical stress on the polymer melt is minimized, PET processed on the MRS extruder has excellent optical and mechanical properties.

The new MRSjump has a longer, modified version of the Multi Rotation Section, which ensures both a longer residence time of the material and more surface area exchange under vacuum. The longer Multi Rotation Section, coupled with a powerful vacuum system operating at 1 mbar, can be used to boost the viscosity of R-PET and to hold it at a stable level in spite of variations in the input material. Therefore, there is no need for any liquid phase (LSP) or solid state polymerization (SSP). With the stabilization and/or increase of the intrinsic viscosity in the extrusion process, the MRSjump is especially well suited to recycling e.g. PET film waste or fiber reclaim – applications for which direct recycling with one single extrusion step was previously impossible due to low intrinsic viscosity or variable input viscosities. In combination with Gneuss’ Rotary Filtration Technology, a high melt purity is guaranteed. Quality assurance can be provided with an online viscometer VIS for measuring melt viscosity.

As demand for PET bottle flakes outpaces supply and processors are looking for alternative feedstock (e.g. to fullfil recycled content mandates) the MRSjump offers an excellent solution for PET thermoform, film or fiber recycling, while the newly developed MRS cutter compactor makes it possible to use low bulk density materials.

OMNIboost Recycling Machine including polyreactor JUMP

The OMNIboost Recycling Machine with an polyreactor JUMP processes PET waste, whether form from industry or postconsumer, directly into high-quality products. The integrated JUMP can lift the IV value of a PET melt up to 0.95 dl/g.

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In the JUMP the polymer passes over several slow turning elements which create a polymer film, the surface of which is constantly renewed. The reactor vessel is kept under vacuum, through which volatile substances are reliably removed. By regulating the residence time in the reactor, the vacuum, the fill level and the speed of rotation of the agitating devices, the polycondensation reaction can be altered to achieve the required product properties. The JUMP is a robust and reliable liquid state polycondensation system (LSP) and a compact, quick and efficient alternative to conventional solid state systems (SSP). It enables direct reintroduction of the polymer into the production process without the need to remelt the PET.

 

OMNIboost Recycling Machine with JUMP polyreactor, MRS Extrusion System, Rotary Filtration Systems and 3C Rotary Feeder.

 

Gneuss Filtration Technology

Tailor-made retrofits of pressure- and process-constant Rotary Filtration Systems

The continuous Rotary Filtration Systems are characterized by a filter disk on which the screen cavities are located in a ring pattern. Screens can be changed on the part of the filter disk that is not active in the melt channel, while the production process continues to run without any interruptions or disturbances.

Gneuss’ top model, the RSFgenius, operates with an integrated back-flushing system offering self-cleaning for very demanding applications and highest quality requirements. Screens can be automatically re-used up to 400 times and filtration finenesses below 10 microns/1200 mesh are available.

Retrofitting a fully-automatic RSFgenius to an existing extrusion line, whether in a pelletizing, sheet, fiber or pipe application, permits the use of more contaminated (and often cheaper) material and/or the use of finer screens. Every retrofit is tailor-made and usually without the need to move any existing equipment.

 

Patented Rotary Filtration System RSFgenius.

 

Gneuss Measurement Technology

Measuring Technology for Extrusion – Flexible, Fast, Safe, Digital

Gneuss provides flexible sensor solutions for pressure and temperature measurements, individually tailored to your application. Abrasion, corrosion, temperature, Gneuss offers the right solution for every challenge.

Gneuss delivers fast. Whether standard sensor or application-specific customized solution. The flexible manufacturing structure allows shortest delivery times.

Gneuss creates safety. In addition to standard-compliant pressure monitoring, Gneuss offers the necessary quality assurance of the measuring equipment.

Gneuss is digital. The latest generation of Gneuss sensors and pressure monitors communicates completely digitally. Integrated RFID chips for digital gauge monitoring are available for all sensor models.

 

Gneuss sensors with digital gauge monitoring.

 

www.gneuss.com

 

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