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

Recycling of plastic films

Starlinger

Moscow, January 25, 2012

Paul Niedl. Head of Sales- recycling technology

Table of content

• company introduction

• film recycling: definitions and applications

• machinery and equipment

company introduction

• 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

recoSTAR basic recoSTAR PET iV+ viscoSTARrecoSTAR universal

film recycling:

definitions and applications

Sources of waste- Definitions

• Production waste

- In house recycling

- Post industrial recycling

- Toll recycling

• Post consumer waste

Recycling of plastic filmsPage 7

• Inline or Offline recycling?

• Different shapes of waste (from light-weight blown film to hard-to-grind start-uplumps) 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)

Issues inhouse recycling

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?

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

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

machinery and equipment

recoSTAR basic and recoSTAR universal- process flow

• extrusion and pelletising of plastic films

• difference is pre-treatment section only

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

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

• Material is fed without precutting into recycling line.

• Feeding per conveyor belt and/or nip roll feeder and/or edge trim cyclone possible.

recoSTAR universal- feeding options

• 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

recoSTAR universal- single shaft cutter

• 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.

recoSTAR basic- working principle

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.

• 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

Extruder

• 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

Double piston filter Double piston backflushing filter

Continuous melt filter without and with backflushing

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

• 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

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 %)

Water Ring 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

Strand Pelletizer

• all thermoplasts

• cylindrical pellets

+ automatic operation

+ flexible application

+ broken strands are automatically re-inserted

+ for high througput

- investment

Automatic Strand 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

Under Water Pelletizer

Under Water Pelletizer with inline crystallisation

• for PET:~15% crystallinity,

+ additional savings on energy consumption.

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

Available machine capacities

• The full Starlinger recoSTAR product range installed

• Laboratory for MFR, IV, color, moisture, impurity and other tests

• Trials for clients

• R&D internally

Technical Center in Weissenbach near Vienna

Thank you for your participation

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

recycling line

offline recycling

recycling technology

right recycling equipment

consumer recycling sorting

plastic films difference

equipment nd page

applications nd page

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