RECYCLING LINES | TECHNOLOGY
increased production output and system efficiency significantly. The system’s SmartFeeder has been made larger and uses more powerful drive motors with a low energy class. The company said it has also significantly simplified and shortened machine maintenance. Together with the optionally available StarLogger software, which ensures accurate data recording, and Starlinger’s “Dynamic Automation Package plus” which now features a convenient automatic on/off function, the new system is easier and more user-friendly to operate. Starlinger’s RecoStar Dynamic Art recycling systems are particularly suitable for heavily contaminated post-consumer plastic waste that has a high moisture content due to storage or after washing. Recycling and the circular economy were a major focus for KraussMaffei at its Extrusion TecDays event in Laatzen, Germany in March. The company revealed a new machine concept for controlled upcycling of PCR plastics into high-qual- ity automotive compounds. The company’s ColorAdjust system ensured precise, reproducible colours. There was also a demonstration of energy- efficient and scalable production of food-grade rPET granulates.
Alongside live demonstrations, the TecDays
provided insights into various recycling processes. Mechanical, solvent-based, and chemical methods were presented, along with the latest developments in the Circular Economy. Expert presentations from industry partners such as PureCycle Technology, Veolia, Lober, Polymetrix, and Exxon Mobil, as well as from leading research institutions like IKV Aachen and IKK Hannover, offered valuable insights into current developments and trends. The program was complemented by forward-thinking technologies such as AI in compound development, smart sensors for inline quality monitoring, and solutions for cable compounds in an electrified future.
Partnerships
In addition to mechanical recycling applications, Farrel Pomini’s Farrel Continuous Mixer (FCM). technology plays a key role in pyrolysis recycling. For example, the company’s partnership with Lummus Technology and its Green Circle business unit takes streams of PCR and post-industrial waste and converts it into gas, pyrolysis oil, and pitch product. The FCM melts feedstock resins and homogenises them under specific temperature and pressure parameters, then they enter a melt tank and pass through the pyrolysis reactor before continuing through a separation process to produce pyrolysis oil, which is subjected to a cracker and turned into saleable post-use products.
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October 2025 | PLASTICS RECYCLING WORLD 15
In another pyrolysis project, Farrel teamed with
the UK’s WF Recycle Tech to recover carbon black from end-of-life tyres. WF Recycle-Tech’s patented pyrolysis system relies on the FCM for the primary stage of heating and homogenising. “The FCM is extremely versatile,” explained Farrel Pomini Presi- dent Paul Lloyd. “Its low process temperature, short residence time and efficient rotor shear make it ideal for processing temperature-sensitive materials or those with prior heat history. Conversely, it can also operate at very high temperatures, making it well-suited for demanding recycling applications.” Two more areas in which Farrel Pomini’s com- pounding expertise is promoting efficiency are in the direct extrusion of composite decking and the processing of recycled rigid PVC. The company says it eliminates traditional finishing requirements with its newly designed Dry Face Pelletizer (DFP). The process begins with compounding rigid PVC with the FCM to a hot-feed single-screw extruder for pelletising. The PVC cools, then the DFP minimises die pressure and temperature increases to cut pellets and after this step, an air transfer system completes the cooling process. This cost-effective concept eliminates further processing.
Above: Recycling was a key theme at KraussMaffei’s Extrusion TecDays event
IMAGE: KRAUSSMAFFEI
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