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Starlinger

Starlinger. Recycling of plastic films. Moscow , January 25, 2012 Paul Niedl. Head of Sales - recycling technology. Table of content. company i ntroduction f ilm recycling: definitions and applications machinery and equipment. c ompany introduction.

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Starlinger

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  1. Starlinger Recycling of plastic films Moscow, January25, 2012 Paul Niedl. Head ofSales- recyclingtechnology ND

  2. Table of content • company introduction • film recycling: definitions and applications • machinery and equipment ND

  3. company introduction ND

  4. Family owned business, founded 1835 in Vienna • World leader in machinery for woven packaging • Diversified in Business Units • Recycling equipment since 1987Business unit since 2002 • 550 employees in Austria (Vienna,Weißenbach) • Regional hubs for sales, service and parts • Turnover of appr. USD 250 million ND

  5. recoSTARbasic recoSTAR PET iV+ viscoSTAR recoSTAR universal ND

  6. film recycling: definitions and applications ND

  7. Page 7 Sources of waste- Definitions • Production waste - In house recycling - Post industrial recycling - Toll recycling • Post consumer waste ND

  8. Page 8 Issues inhouse recycling • Inline or Offline recycling? • Different shapes of waste (from light-weight blown film to hard-to-grind start-uplumps) needs to be handled • Recycling line has to be operated in addition to the production lines • Material management for waste has unfortunately not highest priority- • -but decent material management avoids contamination • High amount of re-granulate should be (directly) fed back into production line without influencing film quality • Edge-trim recycling must be completely automatic (e.g. stand-by mode when film line is stopped) ND

  9. Page 9 Issues post industrial recycling • Different materials: Quick changeover required • Mixing of different material from clients must be avoided- - if toll recycling • Mixing of different material to increase value or decrease cost- - if not toll recycling. Issues post consumer recycling • Sorting required? • Washing or Dry-washing required? • Economically feasible? ND

  10. Page 10 Film recycling: A wide range from commodity to specialty • single layer unprinted • multilayer materials • machine direction or bi-axially oriented film • material partially or heavily printed- influence on re-use • metallised • humidity from outside storage or hygroscopic humidity • solid contamination could be a demanding job for melt filtration • ultra fine filtration ND

  11. Page 11 Film recycling: A wide range from commodity to specialty • LLDPE, LDPE, HDPE • OPP, BOPP, PP • BOPA • BOPET • PLA and other bioplastics • and others • Pick the right recycling equipment depending on the requirements • recoSTARbasic orrecoSTARuniversal ND

  12. machinery and equipment ND

  13. recoSTARbasicandrecoSTAR universal- processflow • extrusion and pelletising of plastic films • difference is pre-treatment section only ND

  14. agglomerator/extruder combination precutting may be required depending on input material higher moisture possible inline application, high automation poss. single shaft cutter/extruder combination no precutting required cold cutting & feeding high automation Page 14 recoSTAR basic recoSTARuniversal ND

  15. Page 15 recoSTAR universal- workingprinciple • Single shaft cutter connected parallel to single screw extruder • Material gets cut in single shaft cutter and cold fed with speed controlled dosing screw into extruder • Exact dosing of material and control of output possible thanks to three drive design ND

  16. Page 16 recoSTAR universal- feedingoptions • Material is fed without precutting into recycling line. • Feeding per conveyor belt and/or nip roll feeder and/or edge trim cyclone possible. ND

  17. Page 17 recoSTAR universal- singleshaftcutter • Single shaft cutter runs slowly and is water cooled or oil heated. Single shaft cutter will automatically reverse and cut loose. • “Cold” cutting • Round hopper bottom & pusher avoids bridging • Bearings fixed outside of cutting chamber, central greasing system. • High storage capacity reducing operator interference • Knives turn able increasing life-time • Exact cutting geometry/high output/low energy ND

  18. Page 18 recoSTAR basic- working principle • material gets cut, dried and thermally compacted in the agglomerator drum • pre-heating of material by friction • temperature raised to just under melting point • rotating disc (400-700 rpm), stainless steel with knives • continuously feeding of compacted material into extruder by centrifugal force • rate of material feeding is controlled automatically by load of agglomerator motor. ND

  19. Page 19 recoSTARbasic- feedingoptions • Precutting may be required depending on material to be processed. • Feeding per conveyor belt and/or nip roll feeder and/or edge trim cyclone possible. ND

  20. Page 20 Extruder • Single screw extruder with air cooling. • 24 L/D w/o degassing, 40 L/D w/ degassing. • Smooth metering zone. • Vacuum degassing reduces moisture, ink, spin finish • Non-sensitive water ring vacuum pump (option rotary vane high vacuum pump) • Impurities are captured in oil condenser for proper disposal. • Closed circuit with heat exchanger in stainless steel. • Heavily printed film up to 100% and/or multi color:- 2 degassing extensions to a total 56 L/D- adding of CaCO3 powder to avoid ink build up ND

  21. Page 21 Continuous melt filter without and with backflushing • Automatic filter, no production stop for screen changing process • Backflushing filter extends service life of screens • Design: Straight melt flow, no dead spots, big open screen surface, deaeration valve Double piston filter Double piston backflushing filter ND

  22. Page 22 Continuous melt filter with Power backflushing • for processing of material with higher degree of contamination • for processing of material with expected contamination peaks • power backflush pressure providedby external hydraulic cylinder  i.e. filter will be flushed with high pressure • pressure constant, back flush separated • piston cleanable on complete surface • main advantage: low melt loss during filtration, less filter discs required ND

  23. Water Ring Pelletizer • PE, PS, PP with MFI ≤ 80, PA 6 and others spherical/lenticular granules, low investment, easy to handle, low operating costs • Knife head supported in die head ensuring parallelism • Magnetic clutch for knife head drive • Easy and quick knife change, no adjustment required • Coarse grain separation ND

  24. Page 24 Water Ring Pelletizer • Variety of dies (number / diameter of holes) and knife heads (number of knives) available for different material • Cooling-hose flexible set-up for adjusted cooling time • Centrifuge for excellent drying (< 0.1 %) ND

  25. Page 25 Strand Pelletizer • PET, PA, PP with MFI >80 < 0,3% crystallinity for PET and others. • cylindrical pellets + low investment + flexible application + low operating costs • limited in throughput due to the handling • operator always needed • no automatic operation ND

  26. Page 26 Automatic Strand Pelletizer • all thermoplasts • cylindricalpellets • + automaticoperation • + flexible application • + brokenstrandsareautomaticallyre-inserted • + for high througput • - investment ND

  27. UnderWaterPelletizer • PE, PP max. MFI 200, PET iV > 0.6, PA andothers • PET iV < 0.6 withmelt pump • sphericalgranules • + lowspacedemand • + inline crystallistionfor PET • + for high throughputs • + savings on energyconsumption • + easy handling • - investment • - maintenance ND

  28. Page 28 Under Water Pelletizer with inline crystallisation • for PET:~15% crystallinity, + additional savings on energy consumption. ND

  29. Page 29 Available machine capacities ND

  30. Page 30 Technical Center in Weissenbach near Vienna • The full StarlingerrecoSTAR product range installed • Laboratory for MFR, IV, color, moisture, impurity and other tests • Trials for clients • R&D internally ND

  31. Thank you for your participation ND

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