The availability of PET bottle flake outside the beverage sector is expected to decline continuously in the coming years. Tray-to-tray recycling can close this gap and succeeds particularly easily with a new extruder.

MRS extruder screw with multi-rotation section for efficient degassing and decontamination

16:9

Polyester

Kunststoff Werkstoffe

Thermoplaste

Blasfolienextrusion

Kunststoffverarbeitung: Maschinen und Komponenten

Flachfolien- und Plattenextrusion

Kunststoffverarbeitung: Verfahren

Extrusion

Standardkunststoffe

Polyethylenterephthalat

Folien

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

Kunststoff-Recycling

Kunststoff-Aufbereitung

Kunststoff-Rezyklat

Unique PET Tray-to-Tray Recycling in a Single Extrusion Step

The Alpla Group is investing in an extrusion line for food-grade recycled PET (rPET) from used PET bottles at its Anagni site.15,000 tons of rPET are to be produced annually as a result.

The Alpla Group is investing in an extrusion system for recycled PET at its site in Anagni, Italy

20:7

Verpackungsmittel aus Kunststoffen

Kunststoffverarbeitung

Verpackungstechnik

Unternehmen

kunststoffe.de

Alpla Expediting a Bottle Cycle in Italy

Henkel significantly expands partnership with social enterprise Plastic Bank. The partners opened their first three plastic waste collection centers in Cairo

Henkel and Plastic Bank opened the first three collection centers in Cairo

Polyethylen

Recycling

Umweltmanagement

Kunststoffhandel

Dienstleistungen

Handel

Henkel and Plastic Bank Open First Collection Centers in Egypt

At K 2022, Engel, with its partners Alpla Group, Brink and IPB Printing, is presenting a quantum leap for the packaging industry. Thin-wall containers can for the first time be produced from PET directly by injection molding in only one process step.

Fig. 1. The thin-walled containers are injection molded from rPET.

Spritzgießen

Messe K-Kunststoffmesse

kunststoffe-international.com

Spritzgießwerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Schmelzefilter

Energieeffizienz

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

Spritzgießmaschinen

Kreislaufwirtschaft

Processing rPET by Thin-Wall  Injection Molding

The increasing demand for recyclates and the shortage of food-grade PET flakes pose challenges for batch quality and color consistency.

Repi offers various additives for recycling PET, which can be used, for example, to prevent the material from darkening.

Additive

Compensating for Darkening in Recycled PET

Amcor and Ron Rubin Winery have commercialized a 100% recycled PET wine bottle. The companies worked together to develop the screw-top bottle, which features a silicon oxide barrier coating.

SiOx barrier coating on the inside of the bottle protects the vintner’s new Blue Bin premium wines from degradation.

Verpackungsmaterial

Logistik

Amcor Develops 100% rPET Wine Bottle

RCS Plastics processes PET flakes into high-quality regranulate for preform and beverage bottle manufacturers. To ensure the required food quality of the recycled material, the company relies on Sikora technology for the quality control of the rPET flakes and pellets.

Cedric Steeg, Employee in Quality Assurance, holds material sample in front of the Puritiy Concept V.

Qualitätssicherung

Check Food Quality of Recyclates

Innovative leadership through forward-looking technology concepts. ENTEX Rust & Mitschke GmbH is the leading manufacturer of Planetary Roller Extruders. ENTEX owns more than 160 registered property rights for the continuously developed products and additional systems. The product portfolio also includes tempering systems and calander rolls.

ENTEX Rust & Mitschke GmbH  

https://www.entex.de

Aufbereitungsmaschinen

Biokunststoffe

Compoundieren

Duroplaste

Hochleistungskunststoffe

Silikone

Technische Kunststoffe

Temperieren

Wärmebehandlung

Verbundwerkstoffe / Werkstoffverbunde

Growth in German PET production over the last three years has been above 30 % a year. This is attributable not least to an enormous increase in disposable, non-returnable packaging products made from this material. As a result, technical development has been driven at an above-average rate. 

PET Boom: PET Recycling and Direct Processing 

Polyethylene terephthalate (PET) is the plastic that has experienced the biggest growth in demand over the past few years. This development has been prompted by the use of PET as a substitute for glass in bottles for carbonated beverages and mineral water and, increasingly, for beer too. Above-average growth rates are also expected for PET over the years to come.  

PET Bottles Success Story: Polyethylene Terephthalate (PET)  

The new Vacurema inline strapping technology is tailored for processing PET bottle flake into high-strength PET strapping in a single step. Compared to a conventional complex of individual machines, comprising crystallizer, dryer and extruder, it obtains a cost saving of up to 25 % for input material and an energy saving of more than a third. 

Strapping Band from Flake: Passes the Tensile Test 

Reducing energy consumption, cutting cycle times while making sure manufacturing is reliable and reproducible – those prerequisites are indispensable for plastics producers to provide for more efficiency in production. A manufacturer of injection molding machines has introduced several innovations in the area of PET processing. 

Systemperipherie

PET Processing: Tuning for Preforms 

An Austrian manufacturer of plastics recycling systems has chalked up above-average growth in the field of in-line sheet technology. PET bottle flake can now be processed into PET flat sheet in a single working step. In just three years, the worldwide installed capacity of such systems has more than doubled to 158,000 t. 

Direct Processing: Flat Sheet from PET Bottles 

PET and PA 6 undergo different types of degradation during processing. As hydrolysis is the primary culprit, the raw materials have traditionally been dried prior to processing. An alternative that saves both time and energy is to degas the polymer melt on a single-screw extruder. 

Polyamide

Extruder

Energy Efficiency: Savings with a Single Screw 

The recycling technologies employed to date frequently came up against their performance limits when it came to processing heavily contaminated plastic wastes, and in particular intensively printed film packagings. Thanks to targeted further development it has now become possible to recycle even fully printed and multi-coat printed post-consumer wastes into high-quality regranulate in a single cycle. 

Post-consumer Waste: Printing Inks? No Problem! 

Origin Materials and Husky have successfully processed recyclable PET polymer containing FDCA into preforms.

Origin Materials has polymerized furandicarboxylic acid into the hybrid polymer PET/F. Husky Technologies injection molding machines can be used to mass produce it into preforms.

Origin Materials and Husky Technologies (“Husky”) announced a milestone in the commercialization of PET (polyethylene terephthalate) incorporating the sustainable chemical FDCA (furandicarboxylic acid) for advanced packaging and other applications: Origin successfully polymerized the bio-based sustainable chemical FDCA into the common recyclable plastic, PET, and Husky molded the resulting “PET/F” hybrid polymer into preforms that were then blown into bottles.

Origin expects to develop and sell a family of 100% bio-based, low-carbon PET/F polymers offering full recyclability and superior performance compared with traditional 100% petroleum-derived PET. The material manufacturer anticipates that PET/F will offer “tunable” performance, with properties like enhanced mechanical performance and superior barrier properties enabling longer shelf life controlled by adjusting manufacturing conditions and the quantity of FDCA copolymer.

This innovation demonstrates a pathway for the drop-in market adoption of FDCA to produce superior polymers cost-effectively from biomass using. Origin expects to enable the production of FDCA, PEF (polyethylene furanoate), and PET/F at commercial scale using its patented technology platform, which turns the carbon found in sustainable wood residues into useful materials, while capturing carbon in the process.

“This is a key moment in the commercialization of cost-effective, low-carbon FDCA and PEF and the development of next-generation sustainable polymers generally. We believe these materials have the power to transform plastics and the material economy,” said John Bissell, Co-Founder and Co-CEO of Origin Materials. “We are pleased to work with Husky to achieve this performance milestone, showing the ready processibility of our innovative hybrid polymers using Husky’s commercial-scale injection molding equipment.“

FDCA is a chemical building block with diverse applications including polyesters, polyamides, polyurethanes, coating resins, and plasticizers. FDCA is also the precursor for the next-generation sustainable polymer PEF (polyethylene furanoate). By combining FDCA with PET, Origin has produced PET/F, a “tunable” hybrid polymer offering performance enhancements and full recyclability.

PEF, another product derived from FDCA, offers an attractive combination of sustainability and performance benefits for packaging. Origin’s PEF is expected to be 100% bio-based, fully recyclable, have attractive unit economics, and offer a significantly reduced carbon footprint, with superior strength, thermal properties, and barrier properties compared to today’s widely used petroleum-based materials.

Novel hybrid polymer “PET/F” expected to deliver enhanced performance compared with traditional PET plastic and have up to 100% bio content.

Advanced co-polyester made by Origin Materials and Husky Technologies using PET/F. Resin, mold, and bottle shown.

2023-08-09 - Husky

Injection Molding: Husky Processes New Hybrid Polymer

issue 07/2023

issue 06/2023

issue 05/2023

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