Recycling of plastics: Cost-effective & innovative solutions to meet the industry’s challenges
People all over the world are becoming more aware of sustainability and the need to protect the environment is growing. As a result, the demand for better recycling of plastics grows.
A major challenge for recycling companies is processing the sheer variety of plastics. These range from household packaging to industrial products. Printed films and moist materials are especially problematic and often not very cost-effective.
In this article, we look at these challenges. We also demonstrate how innovative technologies and machines make the recycling of plastics more profitable.
What are the most frequent challenges in the recycling of plastics?
Printed materials
Printing inks on films make the recycling of plastics difficult. On the one hand, printed materials can contaminate machine parts. On the other hand, the different color components ensure that the granulate does not end up with a unicolor.
This means that printed materials cause:
- Lower quality recyclates in terms of the optical and technical properties of the end product
- More complex manufacturing process
- Additional costs due to the extra work
- Downcycling replacing the recycling of plastics
Innovations enable more sustainable recycling of printed plastic films. Advanced technologies are needed that specialize in the efficient removal of printing inks.
Input materials with different moisture contents
Moisture has a negative impact on mechanical properties, which causes problems during processing. The reason for this is that it influences the melting point and viscosity. All this leads to:
- A low-quality end product
- Increased energy consumption
- Corrosion of machine components
- Formation of mold, bacteria and fungi
That is why effective drying processes in recycling plants are crucial. Removing moisture not only improves the quality of the recycled material. The processes in the recycling of plastics also become more efficient.
Wide range of recyclable plastics
There are numerous types of plastic such as PE, PP, PS, PC and PA. Each type of plastic has unique chemical and physical properties that require processes specific to each material.
Recycling machines need to be able to meet the necessary temperature specifications for each type of plastic.
The same applies to the different melting properties. Melt-specific extrusion parameters might be needed to ensure the high quality of the recycling of plastics.
Technological solutions based on ReadyMac 500 and the EREMA technology
The answer to complex problems is research and innovation. Solutions that are sustainable and cost-effective are particularly important for recycling companies.
For the challenges mentioned above, there are now technological innovations that meet all the requirements.
Improved melt filtration for printed materials
Since its inception, EREMA has carried out intensive research on the recycling of plastics. One of the innovations the company invented is the multipurpose screw with patented TVE technology. This ensures improved melt filtration upstream of extruder degassing.
This configuration removes impurities extremely efficiently. The result is high-quality recyclate, which overcomes problems with filtering and sorting printed materials.
Preconditioning Unit (PCU) for improved drying
A preconditioning unit (PCU) shreds, mixes, heats, dries and predensifies the materials to remove moisture.
A PCU keeps the extruder constantly filled, improves the quality of the recycled material and uses less energy. It also minimizes the risk of corrosion and eliminates hygiene problems.
This technology can be found in the ReadyMac 500, for example.
Multipurpose screw for the recycling of various plastics
The innovative multipurpose screw enables the reliable recycling of PE, PP, PS, PC and PA. It is also used in the ReadyMac 500.
This is possible thanks to the melt-specific extrusion parameters and temperatures.
Environmental and cost-effective advantages due to more effective recycling of plastics
Process efficiency and throughput
Due to the consistent and efficient process, it is easy to process high volumes of plastic waste.
Cost-efficient technology
The ReadyMac 500 is a cost-effective solution for the recycling of plastics at a fixed price. This makes it possible to realize a return on investment quickly and to operate economically.
Minimizing waste and losses
Processing printed materials and removing ink reduces the amount of plastic waste that cannot be recycled. This leads to a better yield of high-quality recyclate and reduces losses.
Lower operating costs
The ReadyMac 500, for example, is very flexible when it comes to processing different types of plastic. It also removes contaminants efficiently. This significantly reduces operating costs for recycling companies. The machine also minimizes the need for expensive additional equipment and manual sorting processes.
High-quality recyclates
The ReadyMac 500 uses patented EREMA technology to produce materials of the highest quality. This increases competitiveness in the market. It also meets the increasing demand for environmentally friendly and sustainable materials in various industries.