Extruder features an inverse tangential configuration designed to offer homogenous, efficient feeding.
Erema, based in Ansfelden, Austria, has launched the new Intarema plastic recycling and extrusion system at the 2013 K Show in Düsseldorf, Germany. The company says the innovation is designed to maximize productivity and offer flexibility and easy operation along with considerably lower energy consumption.
The Intarema system features the company’s Counter Current system in the border area of the cutter/compactor and tangentially connected extruder. As a result, the company says, the extruder can handle more feed material in less time. The company says the inverse tangential configuration of the Counter Current system ensures that the extruder screw is filled virtually pressure-free with the preheated material.
"The extruder always has the ideal filling level and is never overfilled, which makes it much better to regulate," says Michael Heitzinger, chief technical officer at Erema.
The company says the new Intarema system is also more flexible and reliable, and can adapt well to input changes because feed material is buffered and homogenized for constant extruder feeding.
The company reports that development trials with in-house waste from linear low density polyethylene (LLDPE) blow film production document the effect of the Counter Current system on the increased process stability, productivity and flexibility of the new Intarema plant. "Besides extremely easy operation, a stable and sensitive recycling process is essential to be able to ensure recycling rates of 100 percent high-quality recyclate in virgin material grade, particularly when processing clean in-house waste from production," Heitzinger explains.
Although input material often fluctuates in terms of moisture, compactness and other parameters, Erema says, the technology is designed to ensure that the throughput and quality of the recycled pellets produced remain at a constantly high level.
Erema says the new system offers flexibility when processing materials with particularly high input moisture and contamination levels, such as washed agricultural films, washed postconsumer film flakes (PE-LD, PE-LLD, PE-HD), films with solid content such as paper, wood or metals and also thick-walled regrind materials from waste automobile and electronic goods, PS cups and PE lids.
The system also features the company’s "Smart Start" concept, allowing many central process steps to run automatically, Erema says. Operators can also save all settings and parameters for the optimum result of a special recycling application under one "recipe name" and call it up through the push of a button, Erema says.
Intarema systems are also equipped with EcoSave technology designed to offer reduced energy consumption, a reduction in CO2 emissions and lower production costs.
Intarema recycling systems are offered in three series, Erema says: The T series features a short single-screw extruder without degassing and is designed for such materials as nonprinted edge trim, cutting waste, rolls and loose leftover film and regrind materials.
The TE series features double degassing for the processing of slightly printed production or industrial waste plus fibers and technical plastics.
The patented Intarema TVEplus extruder system is designed for the recycling of materials that are difficult to process such as heavily printed films or very moist materials. This is made possible through ultrafine filtration, thorough melt homogenization and high-performance degassing in a single step, Erema says.
The company reports that Intarema systems are available for capacities ranging from 50 to 3,000 kilograms per hour.