Gneuss presents complete OMNI recycling plant at the NPE
GNEUSS KUNSTSTOFFTECHNIK GMBH
OMNI Recycling Machines for closed loop recycling
Gneuss’ MRS Extrusion Technology is known as an alternative for the reprocessing of contaminated materials like polyester (PET), polystyrene (PS), polypropylene (PP) or polyethylene (PE). In combination with Gneuss’ highly efficient Rotary Filtration Systems, optimized vacuum technology, an online viscometer VIS and Gneuss Measurement Technology, customizable recycling lines tailor-made for a specific material can be engineered. As an option, material can be fed into the extruder via a 3C Rotary Feeder.
Several Letters of Non Objection (LNOs) from the FDA, EFSA conformity and local approvals in Latin America confirm the decontamination efficiency of the technology.
Typical applications for OMNI Recycling machines include the processing of PET reclaim, such as bottle, sheet regrind or fiber waste, into high quality end products, such as thermoformed sheet (suitable for food contact), staple fiber, POY, FDY, BCF or strapping tapes. In addition, a wide range of input materials such as PS, PP, PE, PLA can be recycled. The OMNI series is also used in the decontamination of post-consumer waste for the production of direct food contact products such as HDPE bottle caps, coffee caps and for odor reduction and degassing of PA, SAN or other polymers.
OMNI 130 Recycling Machine for post-consumer PET reclaim on display at NPE
Gneuss will show a complete OMNI Recycling Machine featuring a Multi Rotation System MRS 130 extruder, a water ring pump vacuum system, a fully automatic melt filtration system RSFgenius 150 and an online viscometer VIS. This machine is designed for the processing of up to 1000 kg/h (2,2000 lbs/h) of undried and uncrystallized polyester (PET) reclaim.
The line on display in Orlando will be delivered to a customer in Peru after the show to process R-PET into a thermoforming sheet.
In addition to its compact design, which requires very little space and can therefore usually be easily integrated into existing premises, the OMNI scores highly in terms of flexibility. The fully automated control of vacuum, extruder, dosing, degassing dwell time and filter exchange ensures a consistently high quality of the end product while allowing the operator to use lower cost input materials. With the tight and varying materials market it is becoming increasingly important to be able to produce regardless of the properties of the input materials, especially in the case of varying and uncertain input qualities in the future.
The compact design also results in very low energy consumption. Any energy used in the extrusion process is designed to be used in the next process step. This not only has a noticeable effect on electricity and gas consumption, but also significantly reduces the CO2 footprint of the recycling process.
Gneuss OMNImax Recycling Machine with MRS extruder and RSFgenius filtration system
Multiple screw extruder MRS
The MRS extruder is based on conventional single screw technology but is equipped with a multiple screw section for devolatilization. It enables very efficient and gentle decontamination of the polymer melt, whilst achieving the requirements for direct food contact standards. In addition, the MRS extruder permits the processing of R-PET directly into high quality end products such as packaging sheet, strapping tape or filaments without pre-drying by using a simple and rugged vacuum system. All this is achieved by means of its unique and patented processing section. The Multi Rotation Section is a drum containing multiple satellite single screws, driven by a ring gear and pinion transmission.
The satellite screws rotate in the opposite direction to the main screw. This disproportionately increases the surface exchange of the polymer melt. A large opening for venting, exposing the full length of the satellite screws, is completely under vacuum. This provides excellent and unrestricted access to the polymer melt, the surface of which is constantly replaced at an extremely high rate by the action of the satellite screws in the multiple screw section. The surface area – and the surface area exchange rate – available for devolatilization are far greater than in other extrusion systems. As the thermal and mechanical stress on the polymer melt is minimized, reclaim processed on the MRS extruder has excellent optical and mechanical properties.
In a single, simple extrusion step, harmful contaminants can be removed so thoroughly that the resulting recycled pellets are safe for use in food contact applications.
The MRS 130 on display at NPE is designed for the processing of 1000 kg/h (2,200 lbs/h) of R-PET or 750 kg/h (1,700 lbs/h) of polystyrene or polypropylene reclaim.
Innovative MRS extruder
Vacuum system
Gneuss has developed its own vacuum systems for the extraction of volatile impurities, some of which have patented separation systems. Due to the large melt surface in the MRS extruder, the suction capacity is considerably higher than in conventional systems, so that large quantities of volatile impurities can be extracted from the polymer and separated from the vacuum flow by means of automated separator systems. In addition to a water ring pump vacuum system, Gneuss also offers deep vacuum systems with appropriate separators.
The vacuum system on display is a water ring pump system designed for vacuums of 25-40 mbar and offers high automation and process control with low maintenance, even in recycling applications.
Gneuss Filtration Technology
Gneuss’ top model, the RSFgenius, operates with an integrated back-flushing system offering self-cleaning for very demanding applications and highest quality requirements. Screens can be automatically re-used up to 400 times and filtration finenesses below 10 microns/1200 mesh are available. There will be an RSFgenius 150 on display, with an active screen area of 450 cm2/70 square inches, for 1000 kg/h (2.200 lbs) of R-PET with a filtration fineness of 75 microns (200 mesh).
Retrofitting a fully-automatic RSFgenius to an existing extrusion line, whether in a pelletizing, sheet, fiber or pipe application, permits the use of more contaminated (and often cheaper) material and/or the use of finer screens. Every retrofit is tailor-made and usually without the need to move any existing equipment.
There will also be an SFneosand a KSF model on display. These filter series also operate continuously and process constant, but do not offer backflushing, therefore these systems are for applications that don’t require self-cleaning.
The SFneos series operates automatically as well as process and pressure constant. It is suitable for a very wide range of applications including foam sheet, battery separator film or PVC, and is characterized by a large active screen surface area compact design, as well as extremely easy and safe operation. Screen changes do not have any influence on the product quality.
The KSF series is designed specifically for applications with frequent material type, grade or color changes as well as for high pressure applications like blown film. The KSF screen changers are compact and offer excellent value for money while permitting simple and quick screen changes on the fly without disturbing the process.
Patented Rotary Filtration System RSFgenius
Online viscometer VIS
OMNI recycling systems as well as any other extrusion line can be equipped with the innovative and compact VIS online viscosity measurement system, which will also be on display at NPE. Using a high-precision, rigid gear pump, a small partial flow of polymer melt is diverted from the main melt channel and forced through a precisely manufactured slotted capillary. The data measured there can be used to improve quality assurance. When processing PET on an OMNI recycling line the viscometer allows precise control of the end product viscosity.
Gneuss Measurement Technology - Flexible, Fast, Safe, Digital
Gneuss provides flexible sensor solutions for pressure and temperature measurements, individually tailored to your application. Abrasion, corrosion, temperature, Gneuss offers the right solution for every challenge.
Gneuss delivers fast. Whether standard sensor or application-specific customized solution. The flexible manufacturing structure allows shortest delivery times.
Gneuss creates safety. In addition to standard-compliant pressure monitoring, Gneuss offers the necessary quality assurance of the measuring equipment.
Gneuss is digital. The latest generation of Gneuss sensors and pressure monitors communicates completely digitally. Integrated RFID chips for digital gauge monitoring are available for all sensor models.
