In the world market for 25 years... for the regeneration of plastics Since 1988 Gamma Meccanica S.p.A. has designed and produced machines and plants to recycle plastics. Continual technological improvements and application research from a highly qualified staff, makes this company one of the main innovators and leaders for the international market. Today the company is present in 5 continents with both offices (United States, Russia, India and China) and by means of over fifty representative agencies to guarantee an effective and timely service in every country of the world. The plants of the Gamma Meccanica S.p.A. are able to recycle a large varieties of materials from different forms: films, bottles, fabrics, yarns, fibers, nonwovens, containers. The main types of plants are: - COMPAC plants, composed of a cutter-compactor, extruder, filter and pelletizer; - CONVENTIONAL plants, composed of grinder or granulator, forced feeder, extruder, filter and pelletizer; - plants for the recycling of PET foil; - GM TANDEM plants for the recycling of heavily printed, high humidity and contaminated materials; - plants for the recycling of BIO-POLYMERS. Every plant is custom designed and built to offer the best performance and yield the best quality granule or end product. Head office & factory of Gamma Meccanica S.p.A. plastic department. Total surface: 26.000 sq. m. 2
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Our quality continues to improve The direction of the technical staff is to build plants that can offer higher quality end product, increased production capacity, more energy conservation and a better cost for the customer. In recent years, our principal efforts have been concentrated on finding ways to increase production and develop a means for significant reduction of energy consumption. In particular, this last directive has helped us realize the ECOTRONIC system. When installed in the COMPAC lines it allows for an energy savings of up to 40%. New centrifuge that reduces the noise pollution. Insulation system on extruder increases energy savings ECOTRONIC system reduces energy consumption by up to 40% and no longer uses water for precision temperature control. Die face pelletizer TDA structure streamlined making it more convenient and functional for the operator. + More energy savings + Increased production capacity + Higher quality end-product + Better service 4
+ More energy savings + Increased production capacity + Higher quality end-product + Better service Today, more than ever, Gamma Meccanica is better able to give customers the most comprehensive plant design specific to their production requirements. This is possible with the addition of a new laboratory pilot plant being used to perform tests on customer supplied materials. Production quality has improved across all GM lines thanks to the new testing capabilities. The most important result is, after all, the quality of the final granule. Tests show the nearly total absence of deterioration of a material after the process of recycling. On most recycled materials with Gamma Meccanica lines the rheological curves overlap almost perfectly, demonstrating the efficiency of existing plants. It is also possible to verify the deterioration and current state of the material prior to processing, and advise the customer what to add to improve the quality of the product during recycling. Adding value, or Upcycling is what we focus on for the customer. The table below indicates results achieved for various types of materials. Production has increased thanks to the improvements made to the plants. Results achieved on GM65 COMPAC pilot laboratory line type of material production - kg/h* HDPE (cartene) 150-200 LDPE 40-50 μm 200-260 PET nonwoven 100-140 XPET chip 120-150 LLDPE+CaCo3 200-260 PP (nonwoven) 200-260 *The production can change depending on the density of the material, degree of pollution, print percentage, and humidity percentage. The granules produced from a GM line have high uniformity and are absent of defects, clumping, twins and gas. 5
Our customer service to offer solutions to measure GM65 Compac new laboratory pilot line for material testing and analysis The new GM65 Compac laboratory pilot line was created to provide precise and comprehensive answers to customers engaged in the recycling of plastics. This line has several characteristics compared to the standard lines that makes it extremely flexible and can easily recycle and test most of the materials on the present market. Companies interested in recycling can test their material on this line and receive reports concerning all possible and relevant data, useful both for the decision to purchase a line, and to discover the maximum quality of the material that can be obtained. The customer can be given enough information to know which line is more suited for their requirements and what production level can be guaranteed. + More energy savings + Increased production capacity + Higher quality end-product + Better service 6
+ More energy savings + Increased production capacity + Higher quality end-product + Better service A laboratory dedicated to the analysis of the materials The test facility is equipped with several instruments, for example: a Melt Flow Indexer that determines the material MFI; and using the capillary rheometer, it is possible to draw the material s rheology curve. After-sales service Gamma Meccanica customers will benefit from our highly trained and experienced technical staff. We also have an extensive inventory of needed spare parts, components and systems that enable our customers to eliminate costly down time. Thanks to special agreements with international forwarding agents and with our office and agency network, delivery of spare parts is guaranteed to all points of the globe. For an immediate answer, Gamma s maintenance and spare parts service is available during business hours and after hours, or for an emergency, via a dedicated telephone line, by fax, internet with remote connection, and diagnostic services 24/7 via modem and/or Ethernet. 7
COMPAC lines The COMPAC regeneration lines are for the recycling of plastics deriving from washing systems, material that has high humidity or print, loose material, roll stock, pre-shredded materials such as fibers, fabrics, yarns and films. The typical composition of every line consists of the cutter-compactor, extruder, filter and pelletizer. This type of line is available in the models Trim-Co, GM65, GM90, GM105, GM125, GM160, GM180, GM210 according to the production capacity. Every line can be customized upon request with additional components (batch systems, controls, safety features, degassing systems, etc...) to satisfy the customers requirements. 8
LINE USED POWER kw/kg PRODUCTION* kg/h TRIM-CO 0.38 40 GM65 0.31 150-260 GM90 0.30 250-420 GM105 0.30 400-680 GM125 0.30 600-950 GM160 0.30 900-1200 GM180 0.30 1500-2000 GM210 0.29 2000-2800 *The productions are referred to LDPE of 40 μm, and they can change depending on the density of the material, degree of pollution, print percentage and humidity percentage. CUTTER-COMPACTOR This system of feeding allows loading of material without presizing as it mills the material by the rotating blades and counterblades located on its inside. During this phase the material is preheated and densified to render it suitable for the phase of extrusion. New ECOTRONIC system The new ECOTRONIC system that is used with the COMPAC system, guarantees a notable energy savings (up to 40%). It avoids the use of water for the control of the temperature, and it offers the possibility to recycle materials with humidity levels from 10 to 15% and it guarantees a higher uniformity of the temperature of the material in the silo of feeding. + More energy savings + Increased production capacity + Higher quality end-product + Better service 9
Conventional lines AF with forced feed The lines for conventional regeneration with the forced feed silo are ideal for the recycling of plastics in films that have been pre-sized prior to reprocessing. The typical composition of every line consists of a grinder or granulator, forced feed, extruder, filter and pelletizer. This type of line is available in the models E-Trim, GM65, GM90, GM105, GM125, GM160, GM180, GM210 depending on the production capacity. Every line can be customized upon request with additional components (batch systems, controls, safety features, degassing systems, etc... ) to satisfy the customers requirements. 10
LINE USED POWER kw/kg E-TRIM 0.5 40 PRODUCTION* kg/h GM65 0.35 180-200 GM90 0.37 250-300 GM105 0.29 400-500 GM125 0.28 550-650 GM160 0.29 900-1100 GM180 0.29 1000-1500 GM210 0.29 1100-1900 *The productions are referred to LDPE and they can change depending on the density of the material, degree of pollution, print percentage and humidity percentage. Forced feed All the components of a Gamma Meccanica regeneration line can be used to retrofit existing extrusions lines and installed on plants of other producers present on the market. + More energy savings + Increased production capacity + Higher quality end-product + Better service 11
Lines for particular productions Lines for PET The lines for the PET recycling are generally composed of conveyor belt, cutter-compactor, extruder, screen changer and pelletizer. The most important aspect when these materials are reprocessed is the necessity to limit the fall of the value of intrinsic viscosity (IV). This value determines the mechanical performances that the material can have. The lines that Gamma Meccanica designs allow for minimal to no loss in IV for some of the worst case materials that have high residual moisture These lines are designed for the regeneration of PA and other hygroscopic materials as well. This type of line is available in the models GM65, GM90, GM105, GM125, GM160, GM180, GM210 depending on the production capacity. COMPAC PET LINES PET INDICATIVE PRODUCTION* kg/h GM65 150-230 GM90 220-420 GM105 420-520 GM125 600-800 GM160 800-1150 GM180 1200-1700 GM210 1600-2200 *The productions are referred to fibers and yarn or light ground film PET and they can change depending on the apparent density of the material, degree of pollution, print percentage, humidity percentage. 12
GM Tandem line for the recycling of heavily printed, high humidity and contaminated materials The tandem line has been designed for the recycling of materials very printed, or with humidity up to 10-15% and heavily contaminated. The plant is composed of a COMPAC feeding technology and two extruders placed in tandem to one another. The effectiveness of the plant is guaranteed by an innovative and patented degassing system. One main benefit of the line is the degassing unit that has a very high efficiency to treat materials with over 100% of print. The gases or the vapors that are formed from the melted material mixed inside the primary extruder are eliminated by the extraction force created by the vacuum. On the secondary extruder an additional degassing system can be installed to expel possible residual gases. Two screen changers can be connected: one after the primary extruder, that expels the contaminating element of greater size and the other after the secondary one that allows the elimination of particles from 50-100 μm. Unit for the hard vacuum installed on Tandem lines. GM lines for the recycling of bio-polymers Gamma Meccanica has since the early 90 s begun a collaboration with companies that produce biodegradable materials. In using the experience and collaboration of the sector experts Gamma Meccanica has been able to produce advanced recycling plants for these materials. A meaningful experience we have is with recycling of PLA, a material that if it isn t regenerated in correct way, isn t suitable for re-use. For this purpose Gamma Meccanica has the experience required for this type of application getting excellent results that have fully satisfied the demands of our customers. ioplastic RECYCLING LINES 13
Extruders The extruder is the fundamental part of any regeneration system, composed of the cylinder, the screw, the variable speed electric motor and the speed reduction gear. The diameter and the pitch of the screw change depending on the type of material to regenerate. The extruder can be equipped with vents and degassing systems to extract the gases produced during the melting of the plastic, avoiding the beginning of defects in the granule such as gas or air bubbles. In our standard design the vents are placed side by side to allow the cleaning from the material without interrupting the vacuum. It is possible to install a variety of dosing systems, for example one placed in around the middle of the length of the extruder to introduce directly in the melt material. This solution yields similar results to that of a twin screw extruder. EXTRUDER Cutting Systems Water ring pelletizer TDA The water ring pelletizer TDA has been conceived with an innovative design that allows an operator a fast start/stop sequence and a rapid material change. It can be installed on lines suited to work most plastics (PE, PP, PS, ABS, MASTER, COMPOUN- DING and other). It is compatible with most if not all the models of extruders currently proposed on the market. The Water Ring Pelletizers TDA are available in these sizes: 2.0, 3.4, 4.0, 5.0, 6.0. 14
The system of opening of the cutting head has been planned to consent to the operator a starting and a size change easy and fast. Underwater pelletizer TI The underwater pelletizer is recommended for the granulation of PET, Nylon and for all plastics with elevated fluidity. The cutting head is entirely underwater to allow the cooling of the material outlet from the die. The materials used for the construction of this machine have highly technical characteristics. 15