VACUREMA Inline Sheet Brochure

www.erema.atWe know how.QM-SYSTEM NACH DIN EN ISO9001QUALITYSYSTEM CERTFIEDTOISO9001Inline sheet production from recycled PET bottle flakeVACUREMA® INLINE SHEETPET bottle flake has become a commodity onthe world market. Besides bottle to bottle recy-cling, the production of PET thermoforming sheetwith the VACUREMA extrusion system is a verycost attractive and profitable business opportu-nity for the reuse of this valuable secondary rawmaterial.Thanks to the system-based very low viscosityloss and extremely stable viscosity providedduring processing, combined with the appropri-ate downstream equipment , it is possible todirectly produce FDA food approved high qualityPET thermoforming sheet with cleanness re-quirements according to ILSI and EFSA, madeof 100% post consumer washed PET-bottle flake.From PET-WASTE direcThe upstream process:Material is fed to a VACUREMA BASIC extrusion system automatically via silo and conveyor screw. It passes a vacuumsluice into the vacuum reactor. In the vacuum reactor the material is mixed, heated, dried and crystallised at thesame time in one working step. Thanks to appropriate dwell time at very high vacuum and very high temperature,residual moisture and moisture variations are removed very efficiently, plus decontamination below FDA levels takesplace.This is essential for minimal IV loss and a product cleanness according to FDA respectively EU-ILSI-regulations.In particular no external predrying of flake before feeding to the system is necessary. In addition to this, the rotatingtools of the reactor provide the force for the efficient and continuous filling of the tangentially and directly connectedsingle screw extruder. The extruder screw takes the material, plastifies, homogenises and degasses it and directs itto a large area fine mesh filter with integrated fully automatic self-cleaning system, another key unit of the process.Proven worldwide: Numerous applicatioVACUREMA BASIC extrusion processconveyor screwvacuum sulicevacuum slidevacuum reactorrotating toolsextruder intakemodified single screw extruderoptional double ventingfine mesh melt filterPETFlake Silo(Basic Layout)Decontamination of processedPET material according toILSI and EFSA.ectly to PET-SHEETtions successful in operation since yearsThe typical downstream process: (provided for example by EREMA-partner SML)Once the melt is free of impurities and gas it is passed through melt pump and static mixer on to a flat sheet die.The melt curtain is polished on a typical 3-roll-stack allowing a thickness range from as low as 150 µm up to approx.1 mm. With this well proven roller arrangement it is possible to achieve a highly polished film surface even withlow viscosity materials such as PET. The integrated gauging system allows an easy control and adjustment of thefilm thickness to achieve the required tolerances. Waterbased antiblock is applied to the film surface to ensure gooddenesting properties of thermoformed articles.A film accumulator and take-off unit is installed in front of the winder to make roll change easy and safe. Final sheetwidth is obtained by an edge trimming station between accumulator and winder. The trim is directly guided to anedge trim granulator and fed back to the extruder. A turret winder produces full width rolls with outside diameterof up to one meter.Thermoforming sheet downstream process (sketch provided by SML)melt pump & static mixermanual diehorizontal or angled 3-roll-stackgauging systemantiblockfilm accumulatoredge trimming stationedge trimming granulatorturret winderFor worldwide representatives see www.erema.atHeadquarters & Production FacilitiesEREMA Engineering RecyclingMaschinen und Anlagen Ges.m.b.H.Freindorf, Unterfeldstraße 3, P.O.B. 38A-4052 Ansfelden/Linz, AustriaPhone +43/732/3190 - 0Fax +43/732/3190 - 23erema@erema.at . www.erema.atSubsidiariesEREMA NORTH AMERICA INC. EREMA JAPAN Co., Ltd. EREMA Shanghai Office23 Old Right Road - Unit#2 8F Tobu Yokohama Second Building Room 1009, Tomson Financial Building,Ipswich, MA 01938 / USA Kanagawa Prefecture 710 Dong Fang Road, PudongPhone +1/978/356-3771 2-15-1, Kita Saiwai, Nishi-Ku Shanghai China (200122)Fax +1/978/356-9003 220-0004 Yokohama, JAPAN Phone +86/21/6876 6201, 6876 6204erema@erema.net Phone +81/45-317-2801 Fax +86/21/6876 6203www.erema.net Fax +81/45-317-2803 erema@erema.com.cnerema@erema-japan.com www.erema.atwww.erema.atPlant sizes availableVACUREMA BASICextrusion system11081109110911091310131013101512151215121514151415141716171620182018downstream typeIII aII bII cIII aIII bIII cIV aIV bIV cV aV bV cVI aVI bVII aVII boutput270 - 330 kg/h300 - 350 kg/h300 - 350 kg/h300 - 350 kg/h400 - 450 kg/h400 - 450 kg/h400 - 450 kg/h550 - 650 kg/h550 - 650 kg/h550 - 650 kg/h750 - 850 kg/h750 - 850 kg/h750 - 850 kg/h900 - 1100 kg/h900 - 1100 kg/h1200 - 1500 kg/h1200 - 1500 kg/hroller width750 mm750 mm900 mm1050 mm750 mm900 mm1050 mm900 mm1050 mm1400 mm1050 mm1400 mm1650 mm1400 mm1650 mm1650 mm1800 mmmax. sheet width500 - 600 mm500 - 600 mm630 - 750 mm800 - 900 mm500 - 600 mm630 - 750 mm800 - 900 mm630 - 750 mm800 - 900 mm1150 - 1250 mm800 - 900 mm1150 - 1250 mm1400 - 1500 mm1150 - 1250 mm1400 - 1500 mm1400 - 1500 mm1550 - 1650 mmthickness range150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µm150 - 1000 µmThe key advantages of VACUREMA INLINE SHEET PLANTS? Cleannes of produced thermoforming sheet FDA approved (suitable for direct food contact) and within EuropeanILSI as well as EFSA limits.? Super high flexibility, very quick material change and color change possible (no external predrying and crystallisingsystems necessary), system processes also virgin pellet and mixtures of pellet and flake, as well as sheet waste preground? The highly effective vacuum-predrying process of the patented VACUREMA extrusion system eliminates moisture variationsof input material before the material is fed to the extruder. This results in an even, continuous high quality filmproduction with widely constant IV independent from input moisture variations.? Sturdy single screw extrusion system, insensitive to solid contamination, providing high melt pressure for a finemesh filtration. Enables filtration before sensitive melt pump.? Large area, super fine 600 mesh / 28 or 32 m melt filtration by the patented EREMA RTF filter system with integratedself cleaning system ensures a high quality end product .? Turnkey supply, on demand also with coextruder(s) for multilayer film Subject to technical modifications. Printed 04/2009_E© EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H.