RECYCLING LINES | TECHNOLOGY
screw is 10 L/D (length-to-diameter ratio) shorter compared to previous Erema double filtration solutions, and there is no longer a need for the discharge metering zone. A dedicated melt pump used to increase the pressure upstream of the second filtration unit ensures the melt is processed more uniformly. “Our DuaFil Compact technology decouples pressure and tempera- ture build-up, which reduces the overall melt temperature so that it
reaches its highest in the ‘plus zone’ of the extruder prior to degassing,” said Clemens Kitzberger, Business Development Manager
segment. “We offer the right systems for specific requirements, including for direct food contact,” said James Qiu, General Manager at Erema Shanghai.
Product quality The central element in Erema’s process is its tried-and-tested Vacurema technology, which was initially launched 25 years ago and has been in continuous development ever since. The main advantage of Vacurema machines is the SafeFlake technology contained in the vacuum reactor, which combines decontamination, drying, and IV treat- ment. When PET flakes are pretreated in vacuum at the correct temperature, moisture and migration substances are effectively removed prior to extrusion preventing any hydrolytic and oxidative decomposition of the melt in the extruder. The quality of the pellets remains consistently high even if the quality of the input varies, while the costs associated with acquisition, ownership, and energy consumption, are comparatively low. “The potential for plastics recycling on the American market is enormous,” said Robert Wahlmüller, CEO of Erema North America, in the run-up to the NPE 2024 exhibition in Orlando, Florida. “Our order books are well filled.” At its NPE stand, the company placed a special focus on the Intarema TVEplus DuaFil Compact double filtration system first launched at K 2022. The system was designed for recycling challenging materials with high levels of contamination and moisture, such as film waste with paper labels, agricultural film, and washed film from household waste. A key feature of the machine is the consist- ently gentle treatment of the melt throughout the entire process, a result of combining the TVEplus system with DuaFil Compact technology. Compact configuration of the machine means the extruder
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of Post Consumer Applications at Erema Group. “This increases the degassing volume by up to 33%, while at the same time reducing retention time and energy consumption.” Since K 2022, Erema has sold around 20
Intarema TVEplus DuaFil Compact systems. One has been delivered to Recupac, a recycling and waste disposal company based in Chile. “As the business unit for waste management at Coipsa, a group of packaging companies in Chile that are fully integrated in all phases of the circular econo- my, we process more than 150,000 tonnes of different materials every year,” said Philippe Morizon, General Manager at Recupac. “With this compact recycling machine, we can produce high-quality pellets that are used to make film and other applications in the packaging sector. There were many arguments in favour of this machine. Particularly important factors were its low energy consumption and high degree of automation, which saves on operating personnel. I am confi- dent we will meet our customers’ expectations, and the initial results are very promising.”
Polyal application Aseptic cartons are composed mainly of cardboard (75%), and have thin LDPE (20%) and aluminium (5%) foils inside, which poses a recycling challenge. The cellulose from the cardboard can be extracted and fed back into the recycled paper chain, leaving a byproduct from the solid residues of PE and aluminium that needs an outlet for its reuse. Bausa- no, the Italian extrusion technology company, has developed a plant to transform the LDPE-alumini- um mixture (called polyal) into core tubes. The polyal recovery plant consists of a single-
screw extruder with double degassing and forced loading system, making it suitable for managing the density of the material and ensuring smooth flow within the machinery. Prior to extrusion, the material undergoes a densification process, which
October 2024 | PLASTICS RECYCLING WORLD 15
Left: The new Intarema
TVEplus DuaFil Compact is significantly shorter than the previous Erema double filtration solution
IMAGE: EREMA
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