Enhancing mixed bottle flakes by turning them into extrudable recycled crystalline polyethylene terephthalate (rCPET) was the goal of a joint development project looking to close the gap in the PET recycling system. By successfully producing a sheet made from recycled material suitable for high-quality applications such as thermoformed food trays, Gneuss, Sukano and Illig have demonstrated that this approach is indeed possible.

Thermally stable rCPET food trays made from multicolor APET bottle flakes

Upcycling of Mixed APET Bottle Flakes into Thermally Stable rCPET Food Trays

Extrusion

Kunststoffverarbeitung: Verfahren

Polybutylenterephthalat

Kunststoff Werkstoffe

Thermoplaste

Farbstoffe und Pigmente

Additive

Schmelzefilter

Kunststoffverarbeitung: Maschinen und Komponenten

Kunststoff-Aufbereitung

Anlagen Lebensmittel

Anlagen für die Additive Fertigung

Anlagen Additive Fertigung / 3D-Druck, andere

Filteranlagen

Farbstoffe

Flakes

Kunststoff-Rezyklat

Extrusionsanlagen

Kunststoff-Recycling

PET: From A to C

Sustainable development is the focus of the Israeli company Tosaf’s trade show presence. The company presents functional, color and combined masterbatches for processing by extrusion and injection molding. These will include color masterbatches for recyclates with a special focus on post-consumer plastics as well as biodegradable masterbatches.

Special masterbatches can be used for permanent orange coloring of high-voltage components in electric vehicles

Masterbatches

Elektromobilität

Mobilität

Messe Fakuma

kunststoffe-international.com

Farbkonzentrate (Batches)

Biokunststoffe

Masterbatches for Current Trends

The plastics industry has a variety of materials and technologies available for significantly reducing the ecological footprint of products. There are very few applications for which it is not possible to replace at least a portion of the fossil material with recyclates or bioplastics. Various methods, standards and software tools are available to determine what savings this can achieve.

Determining CO<sub>2</sub> Savings from Recycled Materials and Bioplastics

Simulation

Software

Recycling

Umweltmanagement

Normen / Standards

Recht allgemein / sonst.

Reducing the CO<sub>2</sub> Footprint

With a newly developed process from Entex it was possible to compound an injection grade compound of PLA with a 50 % wood flour content.

The PLA compound with 50 % wood flour content was successfully produced on Entex’s planetary roller extruder

16:9

Compounding PLA Formulations with a 50 % Wood Flour Content, without Premixing

Compound

Extruder

Kunststoff

Bauwesen

Baustoffe

Compoundieren

Direct to Highly Filled Bioplastics

Drawing on various joint projects conducted with customers, BASF will demonstrate how to significantly improve carbon emissions from products.

Vaude’s outdoor pants use a PA6 from BASF made from chemically recycled car tires. 

Messe K-Kunststoffmesse

kunststoffe.de

Polyurethan

Calculating and Reducing the Carbon Footprint

Under the motto “It‘s all Wittmann”, Wittmann Battenfeld is presenting its machines and systems in the new Wittmann design for the first time.

Automation cell with SmartPlus 90 for manufacturing a spirit level.

Spritzgießen

Schaumspritzgießen

Spritzprägen

Energieeffizienz

Industrie 4.0 für die Kunststoffverarbeitung

Industrie 4.0

Spritzgießmaschinen

Naturmaterialien

Verstärkungsstoffe

Green DC Current for the Injection Molding Machine

This year, the world’s leading trade show K has succeeded in presenting practical solutions for greater resource efficiency on a broad front. A first foray through the trade show grounds.

K 2022 gave numerous practical examples showing visitors how recyclates can be reliably processed with digital aids.

State-of-the-Art Injection Molding Solutions for Greater Resource Efficiency.

State-of-the-Art Injection Molding Solutions at K 2022

Doriat, Clemens, Dr.

Solar / PV

Energieerzeugung

Erneuerbare Energie

Temperiertechnik

Mehrkomponenten-Spritzgießen

Condition Monitoring / Prozessüberwachung

Instandhaltung

Spritzgießwerkzeuge

Werkzeuge für die Kunststoffverarbeitung

Handling, Handhabungstechnik

Automatisierungstechnik

Elastomer-Spritzgießen

Oberflächentechnik

Digitalisierung

Silikonkautschuk

Kautschuk / Elastomere

Kreislaufwirtschaft

It Can Be Done!

The K 2022 offered an immense range of innovations and application examples for – and with more – sustainable materials. Interestingly hereby was that bio-based versions were extremely popular.

Shoes made from waste gas: genetically modified bacteria produce ethanol from waste gas, which is then used to create plastic, e.g. for the Cloudprime shoes from On.

Thermoplastische Elastomere

Silikone

Polyethylen

Streifinger, Florian

Polylactid

Polyamide

Effektpigmente

Polypropylen

Faserverbundwerkstoffe

Andere Werkstoffe

Is Bio the New Standard?

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

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

Verpackungsmittel aus Kunststoffen

Kunststoffverarbeitung

Polyethylenterephthalat

New Hybrid Polymer for Preforms

In Scheplast‘s own words, the company combines injection molding and sustainability. Real ambition or empty promise?

At their site in Schwendi/Hörenhausen,  Scheplast combines plastics processing and farming.

Nachhaltigkeit

Ehrhardt, Melanie

Injection Molding in Rural Idyll

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

Polyester

Blasfolienextrusion

Flachfolien- und Plattenextrusion

Standardkunststoffe

Folien

Halbzeuge und Zwischenprodukte

Kunststoff-Halbzeuge

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

The Danish company Plastix recycles old fishing nets and ropes. The granules produced are used by JSP International, among others, to manufacture expanded polypropylene (EPP).

11 % of the plastic waste in the sea comes from the maritime industry. For the recycling of old fishing nets and ropes, accurate sorting is very important

Expanded Polypropylene from Maritime Plastic Waste

Schaumstoffe und Vorprodukte

Schaumstoffe

Polypropylen-Compound

From Fishing Net to Particle Foam

Process technologies for manufacturing multilayer and multicomponent products offer great potential for using reprocessed plastic wastes even for plastic parts that are subject to strict requirements for surface quality, product protection or consumer safety. The key: to place the recycled material in the interior while the surface is made of virgin material. Engel has developed a variant of sandwich injection molding that allows high proportions of recycled material to be used even with complex part geometries.

The sandwich technology (skinmelt) hides the recycled material beneath a virgin material surface – for example in the transport boxes

Engel’s skinmelt Sandwich Process Paves the Way for Increased Use of Recycled Material

Werkstoffprüfung

Messtechnik

Co-Injektion (Barriere-/Sandwich-Spritzgießen)

Recycling that Gets under the Skin

Smart assistance systems are paving the way for self-optimizing production. Automatic correction of quality-relevant parameters is already reality for individual phases of the injection molding process. At K 2019, Engel presented the iQ weight control with the example of a recyclate application for the first time.

With the manufacture of thin-walled sample parts, Engel presented the  iQ weight control smart assistance system at K 2019, with a recyclate application for the first time

The iQ weight control Assistance System Ensures Higher Process Stability

Werkzeuginnendrucksensoren

Sensoren / Messwertaufnehmer

Steuern, Regeln

Messgeräte für Viskosität

Opening up a Broader Range of Applications for Recyclates

Current requirements for product quality and rising demands for sustainable products are dictating ever stricter requirements regarding the quality of recyclates. Further technological developments aimed at material purity and quality are unavoidable.

Expanded Machine Portfolios from Turnkey Solutions to Integrated Systems

Wiederaufbereitung

Aufbereitungsmaschinen

Circular Economy Is the Buzzword  of the Hour

Bausano Processes Plastics from Recycling and Biomaterials

With the processing of increasingly “green” plastics, Bausano, an Italian manufacturer of extrusion lines, is opening itself up to the circular economy.

“The latest guidelines at European level show that reducing the consumption of virgin material is one of the cornerstones of the new guidelines. The packaging sector is among the areas in which the volume of plastics remains particularly high. To restrict the exploitation of natural resources, it is therefore essential to promote the use of practical, environmentally friendly and efficient alternatives,” explains Massimiliano Fenili, technical manager at Bausano, and continues: “In this context, corporate strategies must be updated to take into account the long-term goals of sustainable development. We regard these changes as an opportunity to find new solutions.”

In this spirit, Bausano develops extrusion lines that can process mixtures of plastics, plant-based components (rice husks, coffee grounds, banana skins, kelp, almond shells, avocado pits, cork and other plant residues) and recyclates.

<ul><li>a wood plastic composite (WPC) formulation, which is also obtained from plastic waste together with the plant components,</li><li>ABS terpolymer (acrylonitrile-butadiene-styrene) obtained from the recycling of waste electrical and electronic equipment (WEEE),</li><li>LDPE from bottle closures containing up to 60 % PCR,</li><li>HDPE from bottles containing up to 60 % PCR,</li><li>WPC based on PLA, with a polylactic acid content of 60 to 80 % and a sawdust content of 20 to 40 % and</li><li>biodegradable thermoplastic PBAT (adipic acid copolyester).</li></ul>

Depending on the type of plastic and application, the E-GO series of single-screw extruders or the MD series of twin-screw extruders process between 100 and 900 kg/h.

Bausano & Figli S.p.A.  

https://www.bausano.com

Bausano tested a wide variety of material mixtures of more sustainable plastics on its extruders. 

2023-04-06 Bausano englisch

Recyclates and Bioplastics in Extrusion

issue 08/2023

issue 07/2023

issue 06/2023

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