Recycling of plastic films Starlinger Recycling of plastic films Moscow, January 25, 2012 Paul Niedl. Head of Sales- recycling technology ND

Table of content company introduction Recycling of plastic films Table of content company introduction film recycling: definitions and applications machinery and equipment ND

Recycling of plastic films company introduction ND

Family owned business, founded 1835 in Vienna Recycling of plastic films 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 2002 550 employees in Austria (Vienna, Weißenbach) Regional hubs for sales, service and parts Turnover of appr. USD 250 million ND

Recycling of plastic films recoSTAR basic recoSTAR universal recoSTAR PET iV+ viscoSTAR ND

film recycling: definitions and applications Recycling of plastic films film recycling: definitions and applications ND

Sources of waste- Definitions Recycling of plastic films Page 7 Sources of waste- Definitions Production waste - In house recycling - Post industrial recycling - Toll recycling Post consumer waste ND

Issues inhouse recycling Recycling of plastic films Page 8 Issues inhouse recycling 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) ND

Issues post industrial recycling Recycling of plastic films 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

Film recycling: A wide range from commodity to specialty Recycling of plastic films 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

Film recycling: A wide range from commodity to specialty Recycling of plastic films 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 recoSTAR basic or recoSTAR universal ND

machinery and equipment Recycling of plastic films machinery and equipment ND

recoSTAR basic and recoSTAR universal- process flow Recycling of plastic films recoSTAR basic and recoSTAR universal- process flow extrusion and pelletising of plastic films difference is pre-treatment section only ND

recoSTAR basic recoSTAR universal Recycling of plastic films Page 14 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

recoSTAR universal- working principle Recycling of plastic films Page 15 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

recoSTAR universal- feeding options Recycling of plastic films Page 16 recoSTAR universal- feeding options Material is fed without precutting into recycling line. Feeding per conveyor belt and/or nip roll feeder and/or edge trim cyclone possible. ND

recoSTAR universal- single shaft cutter Recycling of plastic films Page 17 recoSTAR universal- single shaft cutter 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

recoSTAR basic- working principle Recycling of plastic films 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

recoSTAR basic- feeding options Recycling of plastic films Page 19 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

Extruder Single screw extruder with air cooling. Recycling of plastic films 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

Continuous melt filter without and with backflushing Recycling of plastic films Page 21 Continuous melt filter without and with backflushing Double piston filter Double piston backflushing filter 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 ND

Continuous melt filter with Power backflushing Recycling of plastic films 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 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 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

Recycling of plastic films 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

Recycling of plastic films 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

Automatic Strand Pelletizer Recycling of plastic films Page 26 Automatic Strand Pelletizer all thermoplasts cylindrical pellets + automatic operation + flexible application + broken strands are automatically re-inserted + for high througput - investment ND

Under Water Pelletizer Recycling of plastic films Under Water Pelletizer 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 ND

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

Available machine capacities Recycling of plastic films Page 29 Available machine capacities Extruder Ø Output (w/o venting) Output (with venting) 65 150 – 230 kg/h 130 - 200 kg/h 85 280 – 400 kg/h 230 – 350 kg/h 105 400 – 600 kg/h 350 – 500 kg/h 125 650 – 850 kg/h 550 – 800 kg/h 165 900 - 1400 kg/h 720 - 1300 kg/h ND

Technical Center in Weissenbach near Vienna Recycling of plastic films Page 30 Technical Center in Weissenbach near Vienna The full Starlinger recoSTAR product range installed Laboratory for MFR, IV, color, moisture, impurity and other tests Trials for clients R&D internally basic/universal: Verkürzte Version Vorstellung direct Auflassen der 45 compact und Erklärung, dass dies kein Markt für uns ist recoSTAR universal 165 Unterschiede zum Mitbewerb Q&A ND

Thank you for your participation Recycling of plastic films Thank you for your participation ND