APPLICATIONS SOLUTIONS. and. > Post Industrial > Post Consumer > PET Improvement > Recycling & Compounding ENGLISH.

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1 APPLICATIONS and SOLUTIONS > Post Industrial > Post Consumer > PET Improvement > Recycling & Compounding ENGLISH

2 ONLY THE BEST FROM EVERYTHING NEXT GENERATION RECYCLINGMASCHINEN GMBH Our company combines exemplary, cutting-edge European technology with a global presence. Our exceptional innovation, one-of-a-kind technical expertise and ability to serve as a trusted partner in collaboration, have led NGR customers in more than 80 countries around the world to success with individualized plastics recycling solutions. The unique requirements for the best recycling solution are as unique as our customers. This is why the NGR team is at your side every step of the way with extensive knowledge, years of experience, expert advice during material trial runs in our customer care centers in Austria, the United States or China, the installation of machines on site, employee training, customer service, troubleshooting on site or via remote maintenance platform, spare part delivery, and much more. Contact us with your challenge. What can we do for you? S.M.A.R.T. DIALOG + Monitor performance any time and anywhere using mobile devices + Information is available in real time + Regulating actions can be taken immediately + Automatic indicator for the need for maintenance + Automatically available spare parts lists = Minimization of idle time = Smooth recycling process without production waste = Long-term documentation enables continuous quality improvement S.M.A.R.T. Evolution Taking advantage of the immense benefits of humans and machines communicating with each other: Information in real time, comprehensive documentation of performance data. Profit from long-term analyses that provide valuable knowledge about specific recycling parameters. This insight helps you better understand your process as a whole to allow you to increase quality further and reduce costs. THE PERFORMANCE PACKAGE PROVIDES A BIG BOOST IN OUTPUT RATE for all shredder-feeder-extruder combinations from NGR + Adaptations to the feeder + Adaptations in the extruder intake area + Advanced, computer-aided extruder screw design = Output rate increased by up to 25 % Performance These are the specific, individual changes that work together to enable the immense increases in performance and improvements for all shredder-feeder-extruder combinations. Profit from even higher process stability, higher shredder processing capacity, higher output rate and simplified machine operation. THE EFFICIENCY PACKAGE DOES MORE WITH LESS For all recycling solutions from NGR What challenge does your company have in plastics recycling that needs a sustainable solution? + Improved heat insulation on the extruder housing and connecting elements + Optimal self-regulating shredder cooling + Advanced, computer-aided extruder screw design = Increased energy efficiency up to 15 % Efficiency Customized subsequent developments for NGR recycling solutions unleash their efficient potential together. Profit from minimized expenses and increased profit thanks to decreasing energy consumption with every kilogram of material you process. Alterations in the machine design or in the machine measurements follow state-of-the-art developments and may cause differences from the images and measurements as stated in this catalogue. Output values are based on the recycling of LDPE resp. PET in accordance with the NGR works standards and depend on the specific material type and the material texture. Additionally to the displayed equipment NGR supplies turn-key equipment by complementing pellet transport, conveyors, cyclones and many more. 3

3 ONLY THE BEST FROM EVERYTHING Film Thermoform parts sheets Injection molding parts Woven Non-wovens LDPE Flakes Regrinds PO Mixed fraction HDPE Flakes PP Flakes Fibers Skeletons Woven Non-wovens Bottle flakes Pipes Preforms LDPE + 50% CaCO 3 PP + 40% CaCO 3 PA6 + 15% glass PO + 45% CaCO 3 PET/PA + 55% CaCO 3 POST INDUSTRIAL During plastic converting, the creation of scrap is inevitable but this material can be recycled and used again. NGR recycling systems realize this challenging task to the pinnacle of perfection (ZERO SCRAP production) and make an important contribution to protecting the environment in the process. NGR recycling solutions set the global benchmark in performance, rpellet quality and self-regulation equipment. This incredible technology is continuously being expanded because NGR continues to develop machine components and processing steps. NGR customers can be sure that their material is processed with efficient use of energy and resources. POST CONSUMER More than 300 million tons of plastic are produced annually, 40 percent of which is thrown away after a single use. NGR considers plastic to be a valuable resource throughout its entire life cycle. In order to ensure the long-term usability of this valuable resource, NGR uses its technical problem-solving expertise to develop individually tailored recycling systems in the post consumer area. Top-end quality is essential for becoming established in the recycling market, for reducing raw material costs and for maintaining the potential of plastics for material circulation. This is why NGR develops energy efficient recycling solutions with imum flexibility for a wide variety of input materials, with high throughput and incredibly efficient material handling. PET IMPROVEMENT P:REACT opens a new dimension in the PET improvement process. P:REACT transforms PET from industrial waste or PET bottle flakes into food-grade rpet in minutes. Information from the inline melt characterization is transferred back into the process control system in almost no time at all so that the IV value (intrinsic viscosity) remains as stable as possible and can even be increased beyond the value from the input material. As a result, the ground-breaking new development from NGR provides an impressive demonstration of what the technical innovations can provide a livable future. P:REACT is also of major interest for fiber producers; spinning oils are completely removed without leaving any residue thanks to the newly developed LSP (Liquid State Polycondensation) process intended specifically for P:REACT and producers see new added value opportunities working with cleaned material. COMPOUNDING Having the right homogenization is essential for specifically affecting the property profile of plastics for certain applications. As a result, the diverse range of products and services offered by NGR includes pioneering technology for refining the plastic melt. The outstanding design from twin screw extruder technology makes it possible to add additives, fillers or reinforcing materials in the melt. This makes it possible, for example, to match the mechanical strength, look, feel or even electrical conductivity of the recycled pellets to the desired new material properties with precision. Compounding combined with sophisticated NGR recycling technology opens up new market segments for recyclers and compounders because first-class secondary raw materials with specific properties can be custom-made with consistency. 5POST COMPOUNDING PET IMPROVEMENT CONSUMER INDUSTRIAL

4 E:GRAN CHOPPER-FEEDER-EXTRUDER COMBINATION LDPE Film PP Edge trim PA6 Film PE/PA Film LDPE Film Creates value. In the smallest space. > ONE-STEP Technology > High Performance for a small floor space requirement > One-button automatic On/Off control > For automatic inline production The E: GRAN is the space-saving recycling solution for film processing. The E:GRAN can be used alongside production or stand-alone, processes thermoplastic film edge trim and roll scrap and does so with the most energy-efficient drive and imum ease of use. The innovative cutting intake design ensures optimum film intake. After size reduction and precompression, the material is fed directly to the extruder. With imum process stability and exceptional material quality, the chopper-feeder-extruder combination provides exceptionally economical ZERO SCRAP production. The robust E:GRAN technology stands for high-precision performance 24 hours a day, 365 days a year. However, the next generation of the extremely compact film series can do even more. With increased energy efficiency, the E:GRAN now ensures even higher profitability. Ø B E:GRAN E:GRAN POST INDUSTRIAL

5 A:GRAN SHREDDER-FEEDER-EXTRUDER COMBINATION PE Compound Bottle closures PMMA Injection molding sprues HDPE Nets Bio-degradable Film PP/TPE Tooth brushes PP/EVOH/PP Skeletons Thermoforming PP Bands LDPE Film ABS Bottle caps PP Textile PP Non-wovens PP/PE/PET Laminated Film Strong performance. Compact design. > ONE-STEP technology > Process bulky plastic scrap > One-button automatic On/Off control > DUMP and RUN operation The A:GRAN is a shredder-feeder-extruder combination of the compact class. The A:GRAN processes all types of plastic waste from industrial production, particularly waste from injection molding shops - with minimum energy consumption and imum ease of use. Without additional pre-crushing, the high-performance recycling solution even reprocesses start-up lumps. By means of material-conserving shredding, the A:GRAN provides exceptionally economical ZERO SCRAP production. The next generation of the A:GRAN gives users critical competitive advantages. The all-around performer with space-saving machine dimensions enables quick shutdown and startup ideal for use with a discontinuous flow of production scrap. Ø B A:GRAN A:GRAN POST INDUSTRIAL

6 S:GRAN SHREDDER-FEEDER-EXTRUDER COMBINATION patented by NGR LDPE Film Heavy printed PP Biaxial-orientated film Film extrusion POST INDUSTRIAL HDPE Packging net PEEK Pipes Pipe extrusion HDPE Automotive parts Blow molding For high performers. And high performance. > ONE-STEP technology > Process bulky plastic scrap > One-button automatic On/Off control > DUMP and RUN operation Ø B PP Non-wovens PP Sheets Cut offs, scrap PP/EVOH/PP Skeletons Thermoforming S:GRAN sets standards for the most common output range. It can be used universally and processes all types of plastic waste from industrial production and does so with minimum energy consumption and imum ease of use. S:GRAN S:GRAN S:GRAN Without additional pre-crushing, the patented shredder-feeder-extruder combination reprocesses even thick-walled production scrap. By means of material-conserving shredding, with automatically controlled temperatures below the melting range, the S:GRAN provides exceptionally economical ZERO SCRAP production. S:GRAN S:GRAN S:GRAN The next generation in the evolution of the S:GRAN is ready and redefines the standards for the high-performance model. The all-around talent features significantly increased energy efficiency and an additional improvement in machine output. S:GRAN S:GRAN PP Pressure pipe fitting Injection molding PP Carpets Bioplastics 11

7 X:GRAN SHREDDER-FEEDER-EXTRUDER COMBINATION LDPE Film roles Decored POST INDUSTRIAL EPS blocks Foam extrusion PP/PA Ropes Single rope or as a role PP Carpets As role input Maximum productivity. In grand style. > ONE-STEP technology > Process bulky plastic scrap > One-button automatic On/Off control > DUMP and RUN operation Ø B PE Artificial grass PP Woven sack PP Yarns Agricultural application The X:GRAN is the robust powerhouse for imum output rates. The X:GRAN can be used universally and processes all types and sizes of plastic waste from industrial production and does so with minimum energy consumption and imum ease of use. X:GRAN X:GRAN X:GRAN Without additional pre-crushing, the patented shredder-feeder-extruder combination reprocesses even large bales or carpet blocks. By means of material-conserving shredding, with automatically controlled temperatures below the melting range, the X:GRAN provides exceptionally economical ZERO SCRAP production. X:GRAN X:GRAN X:GRAN New standards will apply in the future for performance in the top performance segment. The X:GRAN has undergone extensive further development. Adaptations have been made that significantly improve energy efficiency and further improve machine output. PP Geotextile Non-wovens PET Lumps Extrusion start-up PA Carpet roles Post industial scrap 13

8 HANDLING DEVICES BEST-PRACTICE EXAMPLE FILM MANUFACTURING SPAIN RETHINK PROCESSES. INCREASE PRODUCTIVITY. Understanding customer needs over the entire process chain and developing customized recycling solutions to meet those needs is a core competence of NGR. With high-quality advice and cooperation as partners, this provides custom-tailored complete solutions, especially for highly advanced production processes. BENEFITS > > Increased productivity Optimized material logistics and high-quality processing turn production waste into high-quality granulate, which is immediately available for the manufacturing process (ZERO SCRAP production). > > Maximum ease of use The entire process can be monitored using a central control unit. The entire reprocessing process boasts a high level of automation. This keeps labor costs to a minimum. MATERIAL Film rolls; length: 3500 mm, diameter: 600 mm REQUIREMENTS simple material handling / de-coring / reprocessing (ZERO SCRAP production) POST INDUSTRIAL THE SOLUTION BEST-PRACTICE EXAMPLE PIPE PRODUCTION BELGIUM A conveying lift is filled with film rolls. A conveyor belt accepts the rolls and transports them to the hydraulic splitter. Then, the foil core is removed manually. Any unwanted residue particles are removed in the wind tunnel. BEST-PRACTICE EXAMPLE INJECTION-MOLDED BOXES GERMANY MATERIAL REQUIREMENTS MATERIAL REQUIREMENTS HDPE/LDPE pipes, length: 4000 mm, diameter: up to 400 mm simple material handling / size reduction / reprocessing (ZERO SCRAP production) HDPE containers/boxes; 1200x1000x600 mm imum size simple material handling / size reduction / reprocessing (ZERO SCRAP production) THE SOLUTION THE SOLUTION A feeding bin is loaded with PE pipes with a length of 4000 mm and the circuit is then started at the central control unit. The pipes are conveyed forwards hydraulically and cut into rings between 500 and 600 mm in size using a guillotine. The rings drop onto the conveyor belt of the S:GRAN (shredder-feeder-extruder combination). A conveyor belt is loaded with containers and boxes, the circulation is then started at the central control unit. The material is conveyed fully automatically through the cutting area. The size-reduced boxes and containers, (approx. 200 x 200 mm) reach the conveyor belt of the S:GRAN (shredder-feeder-extruder combination)

9 F:GRAN FEEDER-EXTRUDER COMBINATION PET Regrind Fibers Simply revolutionary. A revolution in efficiency. POST CONSUMER > Automatic feeder screw control > Anti-Bridging Silo > One-button automatic On/Off control > DUMP and RUN operation Ø F LDPE Flakes Agricultural Film HDPE Flakes Post washing line The F:GRAN ensures high throughput in recycling pre-crushed material, primarily from plastic washing systems. The F:GRAN processes flakes, even of different sizes, and does so with minimum energy consumption and imum ease of use. F:GRAN F:GRAN F:GRAN The feeder-extruder combination implements gentle material handling and a constant throughput rate, also at non uniform material bulk densities. The flakes are agitated by rotors in the silo, a supply tank with a storage capacity of up to 30 m 3. This prevents clumping (bridging) of the material. F:GRAN F:GRAN F:GRAN New F:GRAN system sizes enable solutions to be perfectly tailored to a wide variety of applications. The evolved F:GRAN series for flake processing now works even more profitably thanks to a significant increase in energy efficiency. F:GRAN F:GRAN F:GRAN PP Regrind Injection Molding LDPE Flakes Post washing line 17

10 C:GRAN CUTTER-COMPACTOR-EXTRUDER-COMBINATION PP/PE Mixed fraction Post washing line PP Flakes Post washing line Transforms challenges. Into quality. POST CONSUMER > Processing of wet materials > Optimized material processing > Temperature regulation in the cutter bin > Efficient extruder PO Mixed fraction Pressed post washing line The C:GRAN is the recycling solution for moist materials. Thanks to its exceptional pre-drying properties, the C:GRAN processes films or flakes with a residual moisture of over 4 %. The C:GRAN has a new, evolved cutting geometry. The fast-moving rotating blades in the cutter bin have been combined with efficiently arranged guides at the cutter bin outlet. The material is prepared for the powerful extruder screw. The cutter-compactor-extruder combination of the C:GRAN thus ensures high output rates with outstanding homogenization of the melt. Ø C C:GRAN C:GRAN C:GRAN C:GRAN C:GRAN C:GRAN C:GRAN C:GRAN PP Regrind Injection Molding PP Regrind Post sheet extrusion 19

11 THE ONE-STOP SHOP FOR SUSTAINABLE POST-CONSUMER RECYCLING. Saving resources and creating closed cycles with components proven under real world conditions. NGR implements complete, customized processing solutions for polyolefins from the moment they leave the plastic washing system to the moment they are formed into pellets. In the ONE-STOP shop, NGR customers can find exactly what creates long-term success in post-consumer plastics recycling: Expert consulting that stems from our passion for exceptional material. This expert consulting is the foundation used to develop individually tailored recycling solutions that feature top-end resource efficiency and imum quality assurance in day-to-day use. OBTAINING THE WIDEST VARIETY OF INPUT MATERIALS FOR THE CIRCULAR ECONOMY Optimal system solutions in post-consumer recycling feature imum flexibility for a wide variety of input materials. They ensure, like the F:GRAN flake series or the C:GRAN cutter-compactor-extruder combination, a high throughput rate and the gentlest material handling. BritAS automatic screen changers provide outstanding filtration performance for heavily contaminated plastic melt, especially for materials from plastic washing systems. The NGR COMP series for refining polyolefins generates custom-made, first-class secondary raw materials. CASCADE EXTRUDER: THE SPECIALIST THAT PROVIDES A "PLUS" FOR YOUR SURFACE NGR cascade extruders are the profitable response to processing materials with a large amount of moisture or the tendency to swell thanks to the improved venting performance. NGR cascade extruders provide a dependable "plus" for the venting surface of the plastic melt and ensure highly effective venting. Thanks to the hard vacuum, it is possible to achieve good, uniform recycled pellet quality that is free of gas inclusions and ideal for use in subsequent applications requiring high quality. THE MACHINE THAT ALMOST TALKS: S.M.A.R.T. DIALOG Gapless quality recording is especially critical in compounding to make it easy to classify recycled pellets into quality classes. Being able to trace the production process also opens up a wider range of applications for the recycled pellets. A single control system coordinates the individual components for the entire system in this process, up to and including complex cascade processes. S.M.A.R.T. Dialog gives you a constant overview and the ability to track all process steps in real time. Comprehensive monitoring allows users to take action in a process immediately at just the spot they need to. Long-term analyses are the tool for continuously optimizing the process and being able to imize profit. POST CONSUMER NGR cascade extruders for improved venting for materials containing a large amount of moisture 20 21

12 ABMF AUTOMATIC BAND-MELT-FILTER FILTER AREA [cm 2 ] MELT BUFFER VOLUME V [liter] RECOMMENDED OUTPUT ABMF PP Regrind Injection Molding LDPE Flakes Post washing line ABMF ABMF ABMF ABMF ABMF ABMF ABMF ABMF > 2400 PP Regrind Injection Molding LDPE Flakes Agricultural Film PP Regrind Post sheet extrusion > High filter fineness possible > Extruder operation during filter band feed > very high throughput rates > Regular filter area renewal > Fully automated filtration > very low operating costs These filters are also available in continuous working mode and/or as filter before venting arrangement. POST CONSUMER CBMF NEW CONTINUOUS BELT-MELT-FILTER PO Mixed fraction Pressed post washing line The new CBMF multi-head filter creates new possibilities in melt filtration with its modular design. Currently the screen areas range from 570 to 1050 cm 2. Depending on the combination of CBMF modules up to 4200 cm 2 can be reached. Parallel filter assembly enables large filter areas. The arrangement in a line creates the option of multi-level filtration. > High filter fineness possible > Extruder operation during filter band feed > very high throughput rates > Regular filter area renewal > Fully automated filtration > very low operating costs PP Flakes Post washing line PP/PE Mixed fraction Post washing line 23

13 P:REACTPET IMPROVEMENT SERIES PET Fibre Fibre spinning PET Bottle flakes Mixed post washing line PET Non-wovens Ready. Set. Go. PET Trays Thermoforming PET Preforms Injection molding PET Lumps Extrusion start-up > Continous operation by design > Rapid IV-increase > High decontamination performance > Automatic control of IV-level P:REACT revolutionizes the PET improvement process. In just minutes, it reprocesses PET plastic waste from industrial production and PET flakes into high-quality, food-grade rpet. It does so with exceptional energy efficiency and low operating costs. > FDA approved for 100% food contact > High energy efficiency min min P:REACT P:REACT P:REACT PET IMPROVEMENT P:REACT works according to the newly developed LSP (Liquid State Polycondensation) method. LSP uses the PET melt phase to trigger recondensation of PET. In the PET melt, the reaction speed of PET is significantly higher. It is possible to attain IV values that are even higher than those of the original starting material depending on your requirements. P:REACT With automated control of the dwell time in the melt and of the level of the vacuum, P:REACT allows the desired IV value to be preset reliably. IV fluctuations, such as those in discontinuous processes like SSP, can be kept within even tighter tolerances with the LSP method. PET Film Automotive airbag PET Skeletons Thermoforming PET Wovens 25

14 COMP SERIES CHOICE OF SELECT ADDITIVES TO ACHIEVE A SPECIFIC EFFECT ON THE MATERIAL PROPERTIES CUSTOMIZED MATERIALS IN ONE WORK PROCESS The uniquely wide range of equipment available from NGR enables its clients to process virtually any form of plastic waste into high-quality plastic. This includes films, fibers and even thick-walled thermoplastic components. High-quality filtration technology, powerful venting and efficient processing provide first-class melt. Reinforcing additives > > Glass fibers > > Basalt fibers > > Synthetic fibers > > Glass beads > > Glass bubbles Reactive additives > > Pigments > > Flame retardants > > UV stabilizers > > Lubricants > > Antioxidants Fillers > > Graphite > > Calcium carbonate > > Wood flour > > Talc > > Kaolin The melt is refined using twin screw extruder technology. Additives, fillers and reinforcing materials can be added here to the melt and significantly shape the property profile of the plastic. The results are custom-tailored materials for virtually any requested application area. The series can also produce cost-optimized pellets. With its modular design, the equipment can be combined with proven components in a wide range of configurations to ensure a high level of flexibility. The central machine control system is easy to use and allows users to quickly change equipment parameters. A recipe management system improves traceability and provides consistently high quality that adds value to the newly extracted plastic. Thermoplastics are indispensable as a source of material. With the ability to change the property profile such as mechanical strength, look and feel, electrical conductivity, etc., the efforts of the recycling industry are being rewarded with increasingly better pellet properties. Greater ability to change properties is also opening new market segments for secondary raw materials and thus creating opportunities for recyclers AND compounders. COMBINING RECYCLING AND COMPOUNDING IS ENERGY EFFICIENT Preparing plastic waste requires the production of plastic melt, necessitating the input of energy into the material. The addition of additives in a twin screw extruder enables tailoring the material properties. As the units are stringed together, the material only requires to be molten once saving on energy. REDUCING THE SIZE OF PRODUCTION AREAS AND SIMPLIFYING MATERIAL HANDLING The compact design of the COMP series does not need much space while still providing high output. Material handling is simplified significantly by stringing together both processes. This cuts costs by reducing the time and effort spent on moving material and minimizes the amount of storage space that needs to be kept available. AT YOUR SIDE IN EVERY PROJECT PHASE Starting from the design of new material properties, analyzing recycling material and the desired end product in the lab, engineering the system and prototyping, the individual project phases create the security needed for new paths in product development. NGR is at your side ready to help. NGR COMP series for refining polyolefins COMPOUNDING 26 27

15 10 16, EN MARKETING TOOLS, LINZ/AUSTRIA Next Generation Recyclingmaschinen GmbH HQ, Production & Customer Care Center Europe Gewerbepark 22, 4101 Feldkirchen, Austria Phone +43 (0) , Fax -2 Taicang Next Generation Recyclingmachines, Co., Ltd. Sales & Customer Care Center China No.6, Wuxi Road, Taicang Economic Development Zone, Taicang, Jiangsu , China Phone +86 (0) , Fax Next Generation Recycling Machines, Inc. Sales & Customer Care Center America 3000 Center Place, Suite 100, Norcross, GA 30093, USA Phone , Fax Toll Free (USA only) Text and illustrations may include custom-made and special equipment available for an additional charge. Subject to technical modifications and misprints.