OMNImax
OMNImax recycling systems for the processing of lower viscosity industrial and post-consumer waste.
OMNImax Recycling System
The OMNImax Recycling System features a new 3C Rotary Feeder, an MRS- or MRSpure Extruder, a fully automatic melt filtration system RSFgenius and an Online Viscometer VIS. 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.
Typical applications:
- Polystyrene (PS)
- Polypropylene (PP)
- Polyethylene (PE)
- Polyester (PET)
- Polylactides (PLA)
- Polyamide (PA)
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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 extrusion system.
Extrusion system
Depending on the application, the OMNImax series uses either a modified MRS extruder with a longer multiple screw section or an MRSpure. In contrast ot the OMNI series, the MRS extuder used in the OMNImax has an extended multiple screw section, which ensures efficient and gentle degassing of the polymer at 1-2 mbar and meets requirements for direct food applications. The mutliple screw section also ensures a very effective homogenization of the melt. The large polymer surface enables highly efficient decontamination, mixing and viscosity control, especially with polyester, thus achieving high-quality end products such as packaging sheet, strapping or filaments.
For higher viscous polymers, an MRSpure-Extruder is used, with a melting extruder installed upstream of the multiple screw section. Depending on the requirements, a single or twin screw extruder can be used for melting. The MRSpure is used e.g. in closed-loop recycling of HDPE bottle caps, HDPE milk bottles or LDPE waste.
| MRS Extruder | throughput rate | ||
| PET | 35 – 2.000 kg/h | ||
| PP + PE | 25 – 1.400 kg/h | ||
| PA | 28 – 2.000 kg/h | ||
| PS | 30 – 1.600 kg/h |
RSFgenius rotary filter
The patented Gneuss RSFgenius Filtration System is always used in recycling applications. This model operates with an integrated backflush system for self-cleaning for very demanding applications and highest quality requirements. The screens can be automatically reused up to 400 times and filter finenesses below 10 µm are possible.
Vacuum technology
In order to be able to extract volatile impurities, Gneuss has developed specialized vacuum systems, some of which have patented separation systems. Due to the large melt surface in the extruder, the suction capacity is much higher than with conventional systems, so that large quantities of volatile impurities can be extracted from the polymer melt and separated from the vacuum stream by separation systems. In addition to a water ring pump vacuum system, Gneuss also offers deep vacuum systems with corresponding separation devices.
Online Viscometer VIS
The OMNImax recycling system also includes an online viscosity measurement system if required that enables precise measurement of the melt viscosity. Using a high-precision, high-conveying gear pump, a small partial flow of the polymer melt is diverted from the main melt channel and then forced through a precisely manufactured slotted capillary. The viscosity measured there is directly related to the molecular chain length, on which in turn the mechanical properties such as tensile strength and stiffness depend. Quality assurance can be improved by recording and storing this data through the viscometer.
Example of an OMNImax recycling system
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
Technical options
- Direct adaptation to sheet, strapping tape or fibre
production lines (no need for the intermediate step of
pelletising) - Blending of additives (in pellet or liquid form)
- Highly efficient, process-constant fine filtration
- Individually configured feeding systems, including the
Gneuss 3C Rotary Feeder
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