Starlinger Recycling of plastic films Moscow, January 25, 2012 Paul Niedl. Head of Sales- recycling technology © Starlinger & Co. GmbH. ND © Starlinger & Co. GmbH. Recycling of plastic films Page 2 Table of content • company introduction • film recycling: definitions and applications • machinery and equipment ND © Starlinger & Co. GmbH. Recycling of plastic films Page 3 company introduction © Starlinger & Co. GmbH. ND © Starlinger & Co. GmbH. Recycling of plastic films Page 4 • 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 ND © Starlinger & Co. GmbH. Recycling of plastic films Page 5 recoSTAR basic ND © Starlinger & Co. GmbH. recoSTAR universal recoSTAR PET iV+ viscoSTAR Recycling of plastic films Page 6 film recycling: definitions and applications © Starlinger & Co. GmbH. ND © Starlinger & Co. GmbH. Recycling of plastic films Sources of waste- Definitions • Production waste - In house recycling - Post industrial recycling - Toll recycling • Post consumer waste ND © Starlinger & Co. GmbH. Page 7 Recycling of plastic films Page 8 Issues inhouse recycling • Inline or Offline recycling? • Different shapes of waste (from light-weight blown film to hard-to-grind start-up lumps) 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) ND © Starlinger & Co. GmbH. Recycling of plastic films 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? ND © Starlinger & Co. GmbH. Page 9 Recycling of plastic films 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 ND © Starlinger & Co. GmbH. Page 10 Recycling of plastic films 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 ND © Starlinger & Co. GmbH. Page 11 Recycling of plastic films Page 12 machinery and equipment © Starlinger & Co. GmbH. ND © Starlinger & Co. GmbH. Recycling of plastic films Page 13 recoSTAR basic and recoSTAR universal- process flow • extrusion and pelletising of plastic films • difference is pre-treatment section only ND © Starlinger & Co. GmbH. Recycling of plastic films recoSTAR basic Page 14 recoSTAR universal • agglomerator/extruder combination • single shaft cutter/extruder combination • precutting may be required depending on • no precutting required input material • higher moisture possible • inline application, high automation poss. ND © Starlinger & Co. GmbH. • cold cutting & feeding • high automation Recycling of plastic films Page 15 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 ND © Starlinger & Co. GmbH. Recycling of plastic films recoSTAR universal- feeding options • Material is fed without precutting into recycling line. • Feeding per conveyor belt and/or nip roll feeder and/or edge trim cyclone possible. ND © Starlinger & Co. GmbH. Page 16 Recycling of plastic films recoSTAR universal- single shaft cutter • 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 ND © Starlinger & Co. GmbH. Page 17 Recycling of plastic films recoSTAR basic- working principle • 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. ND © Starlinger & Co. GmbH. Page 18 Recycling of plastic films 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. ND © Starlinger & Co. GmbH. Page 19 Recycling of plastic films Extruder • 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 ND © Starlinger & Co. GmbH. Page 20 Recycling of plastic films Page 21 Continuous melt filter without and with backflushing Double piston filter Double piston backflushing filter • 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 ND © Starlinger & Co. GmbH. Recycling of plastic films 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 ND © Starlinger & Co. GmbH. Page 22 Recycling of plastic films Water Ring Pelletizer • 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 ND © Starlinger & Co. GmbH. Page 23 Recycling of plastic films 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 %) ND © Starlinger & Co. GmbH. Page 24 Recycling of plastic films Strand 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 ND © Starlinger & Co. GmbH. Page 25 Recycling of plastic films Automatic Strand Pelletizer • all thermoplasts • cylindrical pellets + automatic operation + flexible application + broken strands are automatically re-inserted + for high througput - investment ND © Starlinger & Co. GmbH. Page 26 Recycling of plastic films Under Water 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 ND © Starlinger & Co. GmbH. Page 27 Recycling of plastic films Under Water Pelletizer with inline crystallisation • for PET: ~15% crystallinity, + additional savings on energy consumption. ND © Starlinger & Co. GmbH. Page 28 Recycling of plastic films Page 29 Available machine capacities 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 ND © Starlinger & Co. GmbH. Recycling of plastic films Technical Center in Weissenbach near Vienna • The full Starlinger recoSTAR product range installed • Laboratory for MFR, IV, color, moisture, impurity and other tests • Trials for clients • R&D internally ND © Starlinger & Co. GmbH. Page 30 Recycling of plastic films Page 31 Thank you for your participation ND © Starlinger & Co. GmbH.