Waste to Chips / Pellets

Waste to Chips / Pellets

Production waste from film, fibre and also post-consumer bottle flakes are processed to high quality pellets / chips with a high level of purity and can be blended with virgin material in the production extruder.

With this concept, production waste from fibre, film and start-up lumps are placed into a shredder and are transported via a conveyor belt with metal separator into an intermediate container with an agitator. From there, the material is conveyed into the extruder by means of an auger and a crammer feeder.

Alternatively, size-reduced and agglomerated waste can be directly fed into the MRS extruder. The advantage of separating the processing steps of size reduction and extrusion is that the material feed (and therefore the throughput rate) can be equalized and metals can be reliably ejected from the material flow, which is far more difficult to achieve on integrated systems.

The extruder melts the polyester waste gently and cleans the polymer of volatiles such as surface or absorbed water, spin finish oils and other spinning aids or printing inks (film waste) in the MRS devolatilising section. The intensive and highly efficient surface area exchange under vacuum ensures excellent performance. Solid contaminants such as glass, paper and ceramic are removed by the automatic, self-cleaning Rotary screen changer and the finely-filtered polymer melt flows to a pelletising system (chip cutter).

Optionally (for example when higher IV material is required) the polymer melt can be fed directly into the IV boost system JUMP to achieve an exact IV increase before being pelletised.

The pelletising / chip cutting system can be specified as an underwater strand pelletising process for cylindrical chips with subsequent crystallisation or alternatively, as an underwater die face cutting system for spherical chips with residual heat crystallisation. In this way, a high quality pellet / chip can be manufactured from up to 100 % industrial waste.

Application examples:

Pellets for further processing

Pellets for high viscosity applications

Advantages of the Gneuss recycling concepts for pellet / chip manufacture

  • Wide spectrum of pellet properties can be selected
  • Exact, user-defined viscosity adjustment, matched to the requirements of the application
  • User-defined blends
  • Additives for a wide range of different applications are easily introduced into the melt
  • Exploitation of new markets with the sale of high quality chip made from production waste