Film and sheet recycling - the conditions and requirements for a recycling plant manufacturer

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Helen Evans
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DI(FH) Andreas Rößler-Czermak, R&D Engineer e-mail:

1 Film and sheet recycling - the conditions and requirements for a recycling plant manufacturer DI(FH) Andreas Rößler-Czermak, R&D Engineer a.roessler-czermak@erema.at Juni OCS Witten (Germany) 1

2 Overview Global trends and recycling market overview EREMA company profile EREMA technologies for film recycling The challenge of film recycling From a pellet quality to a product quality Conclusions Plastics market overview World thermoplastic consumption Source: EREMA market data base 2

3 Plastics market overview Recovery in europe Mio t Disposal 47 Mio t Converter demand + Import - Export Consumer demand + Import - Export 25 Mio t post consumer waste 6.3 Mio t Recycling 8.6 Mio t Energy recovery production waste recycling Source: plasticseurope Worldwide TREND towards sustainability, recycling, energy-efficiency European Waste Framework Directive (2008/98/EC) Media hot topic Urban Mining Political strategies Consumer demand Oil price 3

4 Overview Global trends and recycling market overview EREMA company profile EREMA technologies for film recycling The challenge of film recycling From a pellet quality to a product quality Conclusions EREMA Group Hard Facts 1983 founded with the idea of Plastics Recycling Turnover EREMA Group Fiscal year 2012/13 over 117 mio Fiscal year 2011/12 over 127 mio Fiscal year 2010/11 over 95 mio Fiscal year 2009/10 over 74 mio Approx. 250 recycling plants a year 100 % privately owned and independent company More than 400 employees worldwide 4

EREMA Group Headquarters, Austria EREMA HEADQUARTERS EREMA CUSTOMER CENTRE PRODUCTION HALL INCOMING Q-CONTROL R&D CENTRE EREMA Group @ work No.

5 EREMA Group Headquarters, Austria EREMA HEADQUARTERS EREMA CUSTOMER CENTRE PRODUCTION HALL INCOMING Q-CONTROL R&D CENTRE EREMA work No EREMA is the Number One in the global market EREMA is represented in all 5 continents Tonnes of steel processed every day Employees have worked for EREMA at the headquarters for more than 10 years 4,000 Employees producing 250 systems yearly 100, Technical trials and experiments for customers per year 12 mill. Over 4,000 EREMA systems in use worldwide Parts available in the company's own highbay warehouse Tonnes of secondary raw material produced annually using EREMA systems 5

Plastic recycling systems EREMA Products HIGH TECH PLASTIC RECYCLING

Systems VACUREMA FIBRE AND TAPE RECYCLING COAX EDGE TRIM RECYCLING KAG

HIGH-CAPACITY MELT FILTRATION MELT FILTERS PELLETISING SOLUTIONS HG D

6 Plastic recycling systems EREMA Products HIGH TECH PLASTIC RECYCLING EREMA T, TE und T/HP HIGH PERFORMANCE DEGASSING TVEplus PET Recycling Systems VACUREMA FIBRE AND TAPE RECYCLING COAX EDGE TRIM RECYCLING KAG PET PREDRYING AND CRYSTALLISING MPR Multi Purpose Reactor HIGH-CAPACITY MELT FILTRATION MELT FILTERS PELLETISING SOLUTIONS HG D LASER FILTERS ASP-CIC Overview Global trends and recycling market overview EREMA company profile EREMA technologies for film recycling The challenge of film recycling From a pellet quality to a product quality Conclusions 6

EREMA plastic recycling systems Applications In-house production waste recycling Post-industrial waste recycling Post-consumer waste recycling

PE, PP, PET, PS, ABS, PA, PC, biopolymers, compounds ) and different plastic form(e.q.

7 EREMA plastic recycling systems Applications In-house production waste recycling Post-industrial waste recycling Post-consumer waste recycling Food contact approved PET recycling For all thermoplastic polymers (e.q. PE, PP, PET, PS, ABS, PA, PC, biopolymers, compounds ) and different plastic form(e.q. film, hollow body/bottle, foam, fibre, tape ) EREMA T, TE, TVEplus Characteristics EREMA cutter compactor + tangential arranged single screw extruder > without degassing T-type > with degassing TE-type Excellent material preparation ensured by large EREMA cutter compactor 7

8 Several functions in one step The EREMA cutter compactor gas removal preheating homogenisation cutting densification storage force feeding Extruder is fed with preheated and homogenous material (temperature, bulk density, humidity size etc.) No air inclusions in the melt Melting with MINIMUM shearing impact Film & sheet recycling INHOUSE & INDUSTRIAL waste PE film (non-printed) PE, PP film (printed) LDPE edge trim Heavily printed PE,PP film LLDPE stretchfilm Bulk density - deal with different shapes and sizes Cleanness - input material without contamination - need to be kept clean 100% re-use - gentle recycling without degradation (short heat history, no oxidation) Homogeneous pellet shape for proper re-use 8

Film & sheet recycling INHOUSE & INDUSTRIAL waste Specially for inhouse

automatic controlled self adjusting Compact plant dimensions EREMA T and

film flakes PP film + papercontamination Mixed plastics, washed film

9 Film & sheet recycling INHOUSE & INDUSTRIAL waste Specially for inhouse applications: Storage clean and short Flexible output rates Fully automatic controlled self adjusting Compact plant dimensions EREMA T and TE KAG TVEplus Film & sheet recycling POSTCONSUMER waste TVEplus Washed PE film flakes PP film + papercontamination Mixed plastics, washed film flakes, multilayer film need homogenisation Need for filtration capacity on a high level (e.q. sand, dust, aluminium, wood, paper) Drying before the extrusion process High Output Degassing AFTER melt filtration to enhance degassing performance 9

10 Overview Global trends and recycling market overview EREMA company profile EREMA technologies for film recycling The challenge of film recycling From a pellet quality to a product quality Conclusions The challenge of (film) recycling: Continously further developed plastics New plastic compounds and products as ingoing material Most of the time no data sheet Continously increasing quality requirements A nice looking pellet is NOT enough! 10

Examples: In the past for food packaging there were mono films or films with 2 layers. Today: a film with 7 layers with barrier-, carrying- and oxidizing layers.

11 Examples: In the past for food packaging there were mono films or films with 2 layers. Today: a film with 7 layers with barrier-, carrying- and oxidizing layers. Dosing of metallocene: if it is not perfect or changed intentionally, the characteristics of the polymer changes. Not only the mechanical and rheological properties, also the processing changes. PET bowls for food, e.g. salad, pizza, cheese etc. is coming more and more, low IV (bottles to sheet), food contact. The real polymer quality can often ONLY be seen in the film Overview Global trends and recycling market overview EREMA company profile EREMA technologies for film recycling The challenge of film recycling From a pellet quality to a product quality Conclusions 11

From a pellet quality to a product quality Light

film inspection Customer needs proved product

line Case by case for and with our customers:

filtersystems Illustration of the distribution

12 From a pellet quality to a product quality Light microscope OCS Blown and Cast Film line with film inspection Customer needs proved product quality Dry air dryer Targets with the OCS film line Case by case for and with our customers: Comparison of gels between different filtersystems Illustration of the distribution of compoundings (Corema) Detection of gas inclusions 70%LDPE, 30%CaCO 3 12

Targets with the OCS film line Comparison of components and recycling systems for R&D: degassing systems and degassing efficiency Filter systems and filter

intensification Further steps development of further know how of defect characteristics Creation of internal working guidelines Creation of internal

13 Targets with the OCS film line Comparison of components and recycling systems for R&D: degassing systems and degassing efficiency Filter systems and filter efficiency Screw types and design Evaluation of r-pellet quality and complete recycling processes Erema as a COMPETENT partner for film and sheet quality intensification Further steps development of further know how of defect characteristics Creation of internal working guidelines Creation of internal standards for defect analysis Acquirement of knowledge of virgin material Erema with OUTSTANDING technology for the complete film and sheet recycling and reuse process 13

Acquirement of knowledge of virgin material what does that mean?

supplier and EREMA have often the same concern: satisfying the same customer!

Acquirement of knowledge of virgin material: example Project together with OEM dust fibre crystal We have

14 Acquirement of knowledge of virgin material what does that mean? Recycling is a daily business and omnipresent Recycling rates are strongly increasing Virgin material supplier and EREMA have often the same concern: satisfying the same customer! As more as we know from your material as better we can satisfy our common customer! Acquirement of knowledge of virgin material: example Project together with OEM dust fibre crystal We have to have the knowledge about the complete processing before, at and after the machine and about the in and out going material quality With the full understanding problems can be solved or avoided 14

15 Overview Global trends and recycling market overview EREMA company profile EREMA technologies for film recycling The challenge of film recycling From a pellet quality to a product quality Conclusions We close the loop.by having the focus on the APPLICATION and the NEEDS of our customers.by supporting our customers with KNOW HOW not only related to the Erema machine.by beeing the EXPERT both film recycling and conventional polymer recycling.by having the complete KNOWLEDGE both PROCESSING and MATERIAL 15

16 Thank you! GLOBAL HEADQUARTERS. PRODUCTION FACILITIES. EREMA Customer Centre. R&D Centre. Linz, AUSTRIA 16

Northeast Resource Recovery Association Annual Conference May 22, Bill Ginn Regional Sales Manager EREMA North America

Northeast Resource Recovery Association Annual Conference May 22, 2017 Bill Ginn Regional Sales Manager EREMA North America EREMA HEADQUARTERS Ansfelden, Austria. < > COMPANY HISTORY MOVIES EREMA is based