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© Starlinger & Co. GmbH. Recycling of plastic films Starlinger ND Moscow, January 25, 2012 Paul Niedl. Head of Sales- recycling technology
© Starlinger & Co. GmbH. Table of content Recycling of plastic films ND Page 2 company introduction film recycling: definitions and applications machinery and equipment
© Starlinger & Co. GmbH. company introduction ND Page 3 Recycling of plastic films
© Starlinger & Co. GmbH. ND Page 4 Family owned business, founded 1835 in Vienna World leader in machinery for woven packaging Diversified in Business Units Recycling equipment since 1987 Business unit since employees in Austria (Vienna, Weißenbach) Regional hubs for sales, service and parts Turnover of appr. USD 250 million Recycling of plastic films
© Starlinger & Co. GmbH. ND Page 5 Recycling of plastic films recoSTAR basic recoSTAR PET iV+viscoSTAR recoSTAR universal
© Starlinger & Co. GmbH. film recycling: definitions and applications ND Page 6 Recycling of plastic films
© Starlinger & Co. GmbH. Sources of waste- Definitions Production waste - In house recycling - Post industrial recycling - Toll recycling Post consumer waste ND Recycling of plastic films Page 7
© Starlinger & Co. GmbH. Inline or Offline recycling? Different shapes of waste (from light-weight blown film to hard-to-grind start-up lumps) 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) Issues inhouse recycling ND Recycling of plastic films Page 8
© Starlinger & Co. GmbH. 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 Recycling of plastic films Page 9
© Starlinger & Co. GmbH. 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 Recycling of plastic films Page 10
© Starlinger & Co. GmbH. 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 recoSTAR basic or recoSTAR universal ND Recycling of plastic films Page 11
© Starlinger & Co. GmbH. machinery and equipment ND Page 12 Recycling of plastic films
© Starlinger & Co. GmbH. recoSTAR basic and recoSTAR universal- process flow ND extrusion and pelletising of plastic films difference is pre-treatment section only Recycling of plastic films Page 13
© Starlinger & Co. GmbH. recoSTAR basic recoSTAR universal 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 ND Recycling of plastic films Page 14
© Starlinger & Co. GmbH. recoSTAR universal- working principle 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 Recycling of plastic films Page 15
© Starlinger & Co. GmbH. Material is fed without precutting into recycling line. Feeding per conveyor belt and/or nip roll feeder and/or edge trim cyclone possible. recoSTAR universal- feeding options ND Recycling of plastic films Page 16
© Starlinger & Co. GmbH. 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 recoSTAR universal- single shaft cutter ND Recycling of plastic films Page 17
© Starlinger & Co. GmbH. 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 ( 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. recoSTAR basic- working principle ND Recycling of plastic films Page 18
© Starlinger & Co. GmbH. recoSTAR basic- feeding options 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 Page 19 Recycling of plastic films
© Starlinger & Co. GmbH. 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 CaCO 3 powder to avoid ink build up Extruder ND Recycling of plastic films Page 20
© Starlinger & Co. GmbH. 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 Continuous melt filter without and with backflushing ND Recycling of plastic films Page 21
© Starlinger & Co. GmbH. 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 provided by 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 Recycling of plastic films Page 22
© Starlinger & Co. GmbH. 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 Water Ring Pelletizer Recycling of plastic films Page 23 ND
© Starlinger & Co. GmbH. 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 %) Water Ring Pelletizer ND Recycling of plastic films Page 24
© Starlinger & Co. GmbH. 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 Strand Pelletizer ND Recycling of plastic films Page 25
© Starlinger & Co. GmbH. all thermoplasts cylindrical pellets + automatic operation + flexible application + broken strands are automatically re-inserted + for high througput - investment Automatic Strand Pelletizer ND Recycling of plastic films Page 26
© Starlinger & Co. GmbH. PE, PP max. MFI 200, PET iV > 0.6, PA and others PET iV < 0.6 with melt pump spherical granules + low space demand + inline crystallistion for PET + for high throughputs + savings on energy consumption + easy handling - investment - maintenance Under Water Pelletizer Recycling of plastic films Page 27 ND
© Starlinger & Co. GmbH. Under Water Pelletizer with inline crystallisation for PET: ~15% crystallinity, + additional savings on energy consumption. ND Recycling of plastic films Page 28
© Starlinger & Co. GmbH. Extruder ØOutput (w/o venting)Output (with venting) – 230 kg/h kg/h – 400 kg/h230 – 350 kg/h – 600 kg/h350 – 500 kg/h – 850 kg/h550 – 800 kg/h kg/h kg/h Available machine capacities ND Recycling of plastic films Page 29
© Starlinger & Co. GmbH. The full Starlinger recoSTAR product range installed Laboratory for MFR, IV, color, moisture, impurity and other tests Trials for clients R&D internally Technical Center in Weissenbach near Vienna ND Recycling of plastic films Page 30
© Starlinger & Co. GmbH. Thank you for your participation Recycling of plastic films Page 31 ND
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