OMNImax recycling systems for the processing of lower viscosity industrial and post-consumer waste.
Gneuss’ MRS Extrusion Technology has proven itself as an alternative for the reprocessing of contaminated materials like polyester, nylon, polystyrene, polypropylene or other polymers. In combination with the highly efficient Gneuss Rotary Filtration Systems and optimized vacuum technology, customizable recycling lines tailor-made for a specific material can be engineered. Several Letters of Non Objection (LNOs) from the FDA, EFSA conformity and local approvals in Latin America confirm the decontamination efficiency of the technology.
- Polystyrene (PS)
- Polypropylene (PP)
- Polyethylene (PE)
- Polyester (PET)
- Polylactides (PLA)
- Polyamide (PA)
OMNI Recycling Sytem for post-consumer fiber or thermoform reclaim
The OMNImax Recycling System features a new 3C Rotary Feeder, an MRSjump 70 extruder, a fully automatic melt filtration system RSFgenius 90 and an online viscometer VIS, for the processing of 200 kg/h (450 lbs/h) of undried and uncrystallized polyester (PET) thermoform reclaim. Thereby OMNImax enables super clean recycling and is suitable for devolatilization, purification, decontamination, odour reduction, filtration and homogenization.
3C Rotary Feeder
The newly developed 3C Rotary Feeder makes it possible to use low bulk density materials without any external processing steps. A conveyor belt feeds shredded reclaim material into the hopper, where a fast-rotating disc with knives cuts, compacts and pre-conditions the material. The knives add energy into the material and start the heating and degassing process before the material is automatically fed into the MRSjump extruder.
|MRSjump extruder||throughput rate|
|PET||250 – 2.000 kg/h|
|PP + PE||180 – 1.400 kg/h|
|PA||250 – 2.000 kg/h|
|PS||200 – 1.600 kg/h|
Detailed information at virtual.gneuss.com
The MRSjump extruder is based on conventional single screw technology but is equipped with a multiple screw section for devolatilization. It enables very efficient and gentle decontamination of PET, whilst achieving the requirements for direct food contact standards. The MRS extruder permits the processing of R-PET directly into high quality end products such as packaging sheet, strapping tape or filaments without pre-drying by using a simple and rugged vacuum system. This is achieved by means of its unique and patented processing section. The Multi Rotation Section is a drum containing multiple satellite single screws, driven by a ring gear and pinion transmission.
The satellite screws rotate in the opposite direction to the main screw. This disproportionately increases the surface exchange of the polymer melt. A large opening for venting, exposing the full length of the satellite screws, is completely under vacuum. This provides excellent and unrestricted access to the polymer melt, the surface of which is constantly replaced at an extremely high rate by the action of the satellite screws in the multiple screw section. The surface area – and the surface area exchange rate – available for devolatilization are far greater than in other extrusion systems. As the thermal and mechanical stress on the polymer melt is minimized, PET processed on the MRS extruder has excellent optical and mechanical properties.
Example of an OMNImax recycling system
- Direct adaptation to sheet, strapping tape or fibre
production lines (no need for the intermediate step of
- Blending of additives (in pellet or liquid form)
- Highly efficient, process-constant fine filtration
- Individually configured feeding systems, including the
Gneuss 3C Rotary Feeder
Advantages of the OMNImax:
- All kinds of input material can be processed, including waste with low bulk densit such as fibre or biaxially oriented film
- Highly flexible: all kinds of materials can be processed, such as PS, PP, PE, PET, PLA, PA
- Super-Clean Recycling Technology: food contact compliance – even for post-consumer input materials, odour reduction
- Minimised residence time, gentle processing and highest quality products
- Closed recycling loop – no downcycling
- Energy efficient, compact lines