FEATURE Drives, motors & controls
SMART DRIVES = SMART SYSTEMS SMART DRIVES = SMART SYSTEMS
A partnership between Nidec Drives and FAE is the power behind the latest extrusion systems for the plastic recycling industry
I
n high-demand industrial environments like plastic recycling and extrusion, system drive reliability are critical to operational
success. FAE, specialists in electrical panel design for OEMs in the plastics sector across Italy and Switzerland, needed a drive solution that could meet the rigorous demands of continuous operation, high power density, and seamless integration with modern control architectures. With a long-standing relationship
withNidec Drives, the company turned toCommander C300and Unidrive M700drives to power its latest generation of extrusion systems. A trusted provider of automation engineering services; FAE aids factories and safely, with less intervention, and following internationally recognised quality management practices. Responding to global competition and market demands FAE adopted Lean Management and Lean Production, so their operations are streamlined manufacturing processes are optimised for better quality and faster delivery. What is a plastic material regeneration
system? Also known as plastic granulation or extrusion recycling, this process converts into reusable plastic granules. These granules support a circular economy by serving as raw materials for new plastic products. To do this, plastic waste is collected and
organised by type such as, Polyethylene Terephthalate, High-Density Polyethylene, Low-Density Polyethylene and Polypropylene. Proper sorting is crucial to ensure quality and avoid contamination. The plastic then goes through a thorough wash to remove dirt, labels, and residues, to prepare for processing. Clean plastic is then shredded into small are fed into ahopper containing a screw mechanism that pushes the material into an extruder. Inside, the plastic is melted and formed into long strands. These strands are
26 February 2026 | Automation
then cooled and cut into uniform plastic granules, also known as pellets, which are then ready for reuse in manufacturing. This process not only diverts plastic from and conserving space, but also lowers the demand for new plastic production, which is energy intensive and reliant on fossil fuels. This places the responsibility manufacturers. By regenerating plastic into reusable granules, OEMs can reduce their carbon footprint and contribute to a more circular economy. Global environmental regulations have tightened, industries are facing increased pressure to adopt sustainable practices, and recycling plastic granules have emerged as a critical resource. Widely used across sectors such as packaging, construction, consumer goods and eco-friendly alternative to new plastic materials. Thus, not only does it support sustainability goals, but also enhances supply chain resilience by reducing dependence on raw petrochemical inputs. Powered by a carefully engineered combination of mechanical precision and intelligent drive control, this complex system relied on Nidec Drives solutions for their ease of integration, compact design, and up key features that align with the demands of their advanced recycling systems. At the heart of the operation are Commander C300 drives, which control conveyor belts, pumps etc, throughout implemented three M700 drives, 500 kW each, a choice driven by their compact
ability to meet power and control requirements without compromising panel space or thermal management.
Commissioning was carried out via Connect
time, compared to other systems that can take up to an hour to program. Nidec Drives intuitive interface allowed FAE to complete the process in just 15 minutes. This ease of programming, combined with competitive pricing and short delivery times, helped FAE stay on schedule and within budget.
The system’s design also accounted for
use, it plays a crucial part when processing lighter materials, helping to ensure consistent feed into the extruder. Thanks to the adaptability of the drive system, integrating this component posed no operational challenges. By selecting Nidec Drives products,
FAE achieved more than just performance, Compared to alternative solutions, the M700 drives reduced panel power dissipation by up to 2,800 watts, resulting in an estimated 24,528 kWh of energy saved annually. This translates to approximately £3,679 in yearly cost savings, based on average industrial electricity rates. The lower heat output also decreased the demand on panel cooling systems, contributing to further operational savings and improved system compact size of the drives, allowed for a more streamlined panel design, maximising space and minimising thermal load. Feedback from technicians and operators has been positive, highlighting the system’s ease of use and minimal technical issues.
Nidec Drives
www.drivesfromnidec.com
automationmagazine.co.uk
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