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Upcycling in the extruder duo: Coperion extruders convert recyclate into quality compound

 |  Subj: Machinery

Twin screw extruders fromáCoperion GmbH ináStuttgart play aákey role inátheáglobalámanufacture ofáhigh-quality compounds. Ináaddition toátheir globalálead position they have acquired anáexcellent reputation inárecent years inámarkets where suchácompounds are made fromárecycled plastics. Here theácombination ofáCOREMA« technology fromáEREMA andátwin-screw extruders fromáCoperion has proven highly successful. Theáinitialástep ofátheárecycling process consists ofáplasticizing andáfiltering ináanáEREMA single-screw extruder witháaácutter compactor. Immediately adjacent toáthis, andáwithoutáallowing theámelt toácool, theácompounding stepጠtheáactualáupcyclingጠfollows ináaáco-rotating ZSK oráSTS twin screw extruder fromáCoperion. This is where theáproperties profile ofátheárecyclate is precisely tailored toátheáspecific requirements. COREMA« gives recycling companies theáopportunity toámanufacture andámarket ready-to-use quality granules withátheánecessary properties foráspecific high-quality applications oráindividualácustomers, thus giving themáaásignificantly larger share ofátheávalue-added chain withinátheáeconomic cycle.

Coperion has been active inátheárecycling market sinceá1992áandáalso offers extrusion systems toáthis sector, sucháasáforátheáreprocessing PET, PP oráHDPE. Based onáthis Coperion launched their cooperation witháEREMA iná2012áandátheátwo technology providers bothácontributed their key competences which complement each other ináanáidealáway. Today, ambitious recycling companies worldwide are using this technology, motivated byátheáuniformly high quality ofátheáoutput materialáandátheáhigh achievable throughput rates ofáupátoá4,000ákg/h (depending onátheámaterial). Overá20áCOREMA« recycling plants equipped witháCoperion twin screw extruders have been sold inátheápastáfour years alone, mainly due toátheáhigh satisfaction customers have experienced withátheáequipment. Theácurrently increasing order intake shows strong evidence ofáaácontinuation ofáthis positive trend. Theáproduced high-quality recycled compounds are used, foráexample, inátheáautomotive andápackaging industries.

Coperion twin screw extruders transformárecycling toáupcycling
Inátheáinitialáprocess step ofátheáCOREMA« system, EREMAĺs robust technology converts input materialsጠsucháasánonwoven PP, PE edge trimmings oráPA fibersጠtoáproduce aáfiltered melt. This melt is then fed intoátheáco-rotating, self-wiping twin screw extruder fromáCoperion, which can be flexibly configured foráallácompounding tasks. Additives, fillers and/oráreinforcement materials are fed intoáits processing section. These may include aáconsiderable proportion ofáCaCO3, talc, fiberglass oránaturaláfibers. Here theámelt also undergoes highly intensive mixing andádevolatilization which are typicaláfeatures ofátheáCoperion twin screw extruders.
Theáinterplay ofáEREMAĺs andáCoperionĺs technologies ensures thatácompounds are treated gently andásubjected toáminimaláthermalástress, becauseátheámelt is passed directly fromáextruder toáextruder withoutáany cooling andáreheating stage. Processing atáaáconstant temperature also provides foráextremely energy-efficient operations. COREMA«ĺs modular plant concept can be optimally tailored toátheáspecific application.

Upcycling asáanáattractive key toáaácyclic economy foráplastics
Theáspectrumáofáplastic waste begins withádomestic packaging waste andáranges througháfilms andácontainers fromáspecific applications andáparts fromárecycling old vehicles, right acrossátoásingle-origin andáoften single-type waste fromáindustrialáproduction. Theáefficiency ofátheáupstreamáEREMA recycling technology enables theáCOREMA« plant toáextend theárange ofáusable waste grades towardsáless expensive recycled raw materials, thus further increasing theáadded value.

Atátheásame time, thanks toátheáproven high compounding performance ofáCoperionĺs twin screw extruders, theáCOREMA« plant increases theávalue ofátheágranules thatácan be produced fromátheáraw materials. This provides recyclers withátheáidealáconditions forátheáeconomic production ofápellets ofáconsistently high quality andámeeting theáspecifications whileáprovidingátheáquantities thatátheáindustry demands.

ôByáconjoining COREMA«ĺs systems witháCoperionĺs technology we can give theámarket aátechnology thatánotáonlyáhelps entrepreneurs achieve commercialásuccess, butáalsoáincorporates basic principles sucháasáresource conservation andásustainability. This is theákey toátheácurrent andáfuture success ofáthis technologyö, says Peter von Hoffmann, GeneraláManager ofátheábusiness unit Engineering Plastics andáSpecialáApplications atáCoperion.

Source: Coperion

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