VACUREMA PET Extrusion Technologies Brochure

www.erema.atWe know how.QM-SYSTEM NACH DIN EN ISO9001QUALITYSYSTEM CERTFIEDTOISO9001PET Extrusion Technologies2Different customer requirements call for different technological solutions.Therefore EREMA offers its VACUREMA system in three different designs, in accordancewith input material, desired IV value and purity requirements placed on the end product.Launched in 1998, the patented process has become the most widely used technologyworldwide for recycling post consumer PET bottle flake.Today, arround 100 customersin all five continents operatewell over 100 VACUREMA plantsin a wide variety of applicationfields, such as bottle-to-bottle,flat sheet, strapping, fibre, etc.New customers are beingadded to the list almost everymonth.Worldwide production capacity of VACUREMA systems (2008)PELLETSTypical dimensions:2.5 mm diameter x3 mm lengthor ball shapeThe ultimate differenceIn the interest of effective IV increase and decontamination, all VACUREMA processes treatflake and not pellets, with the following decisive benefits:DECONTAMINATION TAKES PLACE FASTER AND MORE EFFECTIVELY, since the wallthickness of PET flakes being treated is thinner and their surface area is larger,in comparison to treating pellets. This ensures higher reliability during decontami-nation. A minimum dwell time of several hours to achieve FDA/efsa quality, asrequired with other technologies treating pellets, is not necessary.THE PATENTED VACUUM PREPROCESS AT HIGH TEMPERATURE BEFORE THEEXTRUDER REMOVES RESIDUAL MOISTURE VERY EFFECTIVELY from the startingmaterial and prevents hydrolytic decomposition (IV loss) in the extruder.IV fluctuations resulting from input moisture variations are thus eliminated andthe VACUREMA system can achieve the desired IV increase more effectively and costefficiently (1) than systems with a reactor after the extruder.For the same reason the system can accept starting material with a comparablyhigher residual moisture than other systems, and still output a high IV-quality product.(1) At a throughput of 1,000 kg/h or 6,000 t/year, users save an average of € 100,000 per year on energy alone. The exact potential cost saving depends on each individual situation.Choose between three VACUREMA technologies:BOTTLE FLAKE MATERIALNormally pregroundwith a 12 mm screen,average wall thicknessapprox. 0.1 to 0.4 mmyear 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008600,000500,000400,000300,000200,000100,0000t/yearSURFACE/VOLUMERATIO FOR FLAKES IS2.5 TIMES HIGHERTHAN FOR PELLETS37 convincing reasons … to go for a VACUREMA SYSTEM1. PROVENToday´s most proven and most widely sold PET bottle-to-bottle technology worldwide.Produced pellets highly demanded on the market and easily sell at a good price as a commodity product .2. EXTREMELY FLEXIBLEInput material form variable: the system processes flakes (also light weight bottle flakes), virgin pellets, groundpunched sheet and ground edge trim, among others, also in mixtures.- IV increase adjustable, up to 0.86 and above, depending on throughput and input material.- AA in connection with short extruder and obligatory predryer ahead of preform plants below 1 ppm.- Pellets produced are suitable for use in almost all final application segments.3. HIGHLY EFFICIENT DECONTAMINATION, ULTRA LOW CARBON FOOTPRINTThe decontamination of thin-walled flake in VACUREMA reactors before the extruder takes place faster andmore efficiently, consuming far less energy than the decontamination of thick-walled pellets in conventionalSSP reactors after the extruder.4. ROBUSTFrom practice we know how important robust construction is for a successful, reliable recycling technology.The sturdy and robust VACUREMA single-screw technology with its very short extruder is much more resistantto contamination solids than twin-screw or multiple screw extruders and delivers sufficient melt pressure withoutthe need for a (sensitive) melt pump to meet the quality criteria for fine filtration of solid matter.5. LARGE FILTER AREA FINE FILTRATION OF SOLIDSThe patented melt filtration system supplied as standard with ultra fine 600 mesh/32 m quality screensand very large active filter surface operating at low pressure delivers the cleanest possible BTB repellets. Visible black spots in new PET bottles with high recycled content are either eliminated altogether, or reduced to anabsolute minimum.6. PRODUCED PELLETS IDEAL FOR MIXING WITH VIRGIN MATERIALThe system produces alternatively cylindrically or spherical shaped pellets with the same physical form as virginmaterial. No adjustment of dryers, crystallisers and preform machines is required when VACUREMA repellet isblended in.7. FULLY AUTOMATICState-of-the-art technology featuring innovative process control system software enables extremely straightforwardoperation. Users benefit from start-up at the press of a button and fully automatic continuous operationplus supervision of process parameters, including relevant process data storage."Pushbutton start-up"Over the years EREMA has developed a professional systemfor professional users featuring a fully automatic controlsystem that has greatly simplified operation and reducedthe number of operators required."Pushbutton start-up" is a reality.4 VACUREMA All you need to get started.VACUREMA BASIC - performance data:? Decontamination performance: FDA approved, ILSI compliant , efsa compliant .? Extremely low carbon footprint? High starting material moisture content (up to approx. 1,5%) permissible.? Produces 32 µm fine-filtered, with the consistency and appearance of new rPET pellets; choose between crystallineor amorphous form.? AA in connection with obligatory predryer before preform system generally less than 1 ppm.? Total processing costs from flake to finished rPET pellet only approx. € 0.10 per kg of finished BTB pellets.? Robust single-screw extruder technology, by far not as sensitive to solid contamination as twin screw or multi-screw extruders.? Finished rPET pellet IV can be adjusted, within limits, via throughput .Every VACUREMA BASIC system can be retrofitted if required to upgrade to a fullVACUREMA ADVANCED system or VACUREMA PRIME high-end system.VACUREMA BASIC Extrusion System (Process Layout)Vacuum sluicePatented combinationof vacuum reactor andsingle-screw extruder32 µm high-performance filterwith large activefilter areato pelletisingPET flake (Feeding system not shown)THE HIGH QUALITY, FDA APPROVED BOTTLE TO BOTTLE SYSTEM FOR MARKET ENTRY:If you are looking for an FDA approved, ILSI compliant bottle to bottle system producingultra fine-filtered repellets at lowest possible investment and operating costs - i.e. themost cost-effective method of producing high quality food approved rPET- then you shouldseriously investigate to go for a VACUREMA BASIC system:The system consists in its key components of avacuum reactor, which is linked to a single-screwextruder. The vacuum reactor unit is filled withamorphous, washed PET flakes via a vacuum sluice.Decontamination and perfect predrying of the pro-cessed material takes place inside the vacuumreactor. From the reactor the material is fed at ahigh vacuum into the intake zone of a single-screw extruder. As a result no additional degassingports whatsoever are required on the extruder itself.This dramatically reduces the length of the extruder,minimises its energy consumption, improves colourvalues (B value) of the processed material and keepsAA values to a very low level.In the downstream high-performance, large areafilter the material is fine-filtered by 32 µm meshscreens. This is absolutely essential to produce rawmaterial with a quality similar to that of virgin material.The filter system is equipped with a patented fullyautomatic self-cleaning system that enables longfilter service life despite the very fine level of filtration.After the filtering process the melt is converted intocrystalline or amorphous pellets.Vacuumpump systemFLEXIBLE 5IV change, flake to pellet: minor loss, approx. 1 to 4%Very low carbon footprint: 0.25 to 0.28 kWh/kg total energy consumption onlyVacuum sluiceVACUREMA BASIC FOOD CONTACT APPROVALS/STATUSrPET produced with the VACUREMA BASIC PETextrusion system complies with the followingdecontamination requirements resp. migration levels:Decontaminationperformance accordingto efsa and FDAEuropean efsaEuropean ILSI docs.German BGBIApproved for direct food contact by/in: *US FDAAustriaSwitzerlandCanadaBrasil* … other countries to follow depending on applications byVACUREMA BASIC users.ArgentinaUruguayParaguayetc.*VACUREMA BASIC input to output cleaning efficiency evaluated by “Challenge-Test”Type of artificial inputcontaminationInput concentration [ppm]Output concentrationin finished rPET [ppm]Toluene1866.00.6> 99.9Chloroform28406.8> 99.8Phenyl cyclohexane4370.1> 99.9Benzophenone3062.5> 99.2Lindane6032.2> 99.6Cleaning efficiency [%]32 m fine filter6 VACUREMA Proven standard worldwide.Can be upgradedany time to aVACUREMA PRIMEThe vacuum crystallisation dryer providesadditional predrying and decontaminationof the input material. The material is thentransferred to the reactor of the down-stream VACUREMA BASIC system via adischarge screw. As a result this systemhas all the advantages of the VACUREMABASIC technology, but goes beyond it interms of the IV which can be achieved inthe repellets, and cleaning efficiency. De-contamination performance FDA approved,ILSI, efsa and afssa compliant .Complies with almostall food grade standardsworldwideVACUREMA BASICExtrusion SystemVacuumcrystallisation dryer, continuous operationVACUREMA ADVANCED Extrusion System (Process Layout)32 µm high-performance filter withlarge active filter areaVacuum sluiceto pelletisingPET flake (Feeding system not shown)The patented VACUREMA ADVANCED extrusion system is the first expansion stage of theVACUREMA BASIC technology. Building on the VACUREMA BASIC system, it features anadditional, continuously operating upstream vacuum crystallisation dryer.In the process from flake to repellets as a result this makes IV increases of around2 to 6% possible, depending on the input material.Vacuum reactor,continuous operationVacuum pump system7Flake to pellet IV increase: up to 6%, adjustableTotal specific energy consumption: 0.28 to 0.31 kWh/kg produced rPET onlyVACUREMA ADVANCED FOOD CONTACT APPROVALS/STATUSThe VACUREMA ADVANCED BTB-system has many individualcountry approvals. EREMA can help with country approvalfor any type of VACUREMA technology*n.m. not measurable: residual contamination below 0.1 – 0.3 ppm, not any more traceableVACUREMA ADVANCED input to output cleaning efficiency evaluated by “Challenge-Test”Type of artificial inputcontaminationInput concentration [ppm]Output concentrationin finished rPET [ppm]Toluene1866.0n.m.*> 99.9Chloroform2840n.m.*> 99.9Phenyl cyclohexane437n.m.*> 99.9Benzophenone306n.m.*> 99.9Lindane603n.m.*> 99.9Cleaning efficiency [%]rPET produced with the VACUREMA ADVANCED PETextrusion system complies with the followingdecontamination requirements resp. migration levels:European efsaEuropean ILSI docs.German BGBIFrench afssaApproved for direct food contact by/in: *US FDAAustriaSwitzerlandCanadaBrasil* … other countries to follow depending on applications byVACUREMA ADVANCED users.ArgentinaUruguayParaguayBrand owneretc.*8Feeding(discontinuous)Vacuumpre-treatment units,discontinuousVacuum reactor,continuous operationto pelletising32 µm high-performance filter withlarge active filter areaVacuum sluiceVACUREMA PRIME Extrusion System (Process Layout)PET flake PET flakeVACUREMA BASICExtrusion System VACUREMAThe product (rPET pellets) of this patented EREMA PET bottle flake recycling technologyfulfils and exceeds by far all minimum purity requirements for direct food contact PETpackaging worldwide currently known to EREMA.Building on the VACUREMA BASIC system, this high-end PET extrusion system featurestwo upstream vacuum crystallisation dryers ("vacuum pre-treatment units") operating inbatch mode. This enables very large IV increases and extremely effective cleaning duringthe process.The technology is FDA "C" certified, i.e.universally applicable without restriction forthe reprocessing of PET material flows com-ing from deposit (returnable) systems, mixedhousehold collections (curbside) and alsonon-food packaging (e.g. shampoo bottlesetc.). The technology satisfies by far alsothe European ILSI guideline and efsa regu-lations.Produces ultra clean repelletswith properties and IV like virgin materialSuperior cleaning effect , superior IV increase,superior low carbon footprintThe exceptionally high level of purity in the produced rPET is achievedby an exactly defined and guaranteed minimum treatment timeunder high vacuum and at high temperature for every single thin-walled PET flake particle that is processed.This is made possible by the batch operation of the two parallel arrangedvacuum pre-treatment units, which also act as crystallisers and pre-dryers at the same time. Purity and IV requirements placed on the endproduct (rPET pellets) can be adapted individually and optimally byselecting appropriate batch times.The two identical vacuum pre-treatment units are placed upstream ofthe continuous VACUREMA BASIC extrusion system.Produced pellets meet all purityrequirements for direct food contactcurrently known to EREMA worldwideVacuum pumpsystem(Feeding system not shown)9Flake to pellet IV increase: approx. 6 to 10%, adjustableVery low total specific energy consumption: 0.30 to 0.34 kWhper kg produced rPET pellet onlyVACUREMA PRIME FOOD CONTACT APPROVALS/STATUSn.m.* 0.4 n.m.* 0.7 1.6*n.m. not measurable: residual contamination below 0.1 – 0.3 ppm, not any more traceableVACUREMA PRIME input to output cleaning efficiency evaluated by “Challenge-Test”Type of artificial inputcontamination Toluene Chloroform Phenyl cyclohexane Benzophenone LindaneInput concentration [ppm],input added before washing 1866.0 2840 437 306 603Concentration afterVACUREMA PRIME batchpretreatment, before reactorand extruder [ppm]> 99.9 > 99.9 > 99.9 > 99.9 > 99.9Cleaning efficiency [%]Output concentrationin finished rPET [ppm]n.m.* n.m.* n.m.* n.m.* n.m.*rPET produced with the VACUREMA PRIME PETextrusion system complies with the followingdecontamination requirements resp. migration levels:European efsaEuropean ILSI docs.German BGBIFrench afssaBrand ownerApproved for direct food contact by/in: *US FDAAustriaSwitzerlandCanadaBrasilArgentinaUruguayParaguayBrand owneretc.** … other countries to follow depending on applications byVACUREMA PRIME users.10VACUREMA PRIMEVACUREMA ADVANCEDVACUREMA BASICIV Input FlakeoutputAvailable as an optional extra, the integrated, continuousonline IV measurement , combined with the fully automaticplant control system, makes it possible to keep to therequired IV value at a virtually constant level by controllingprocessing parameters such as vacuum, throughput ,processing temperatures etc., irrespective of fluctuatingexternal influences such as the degree of impurity andresidual moisture of the input material. Available for allVACUREMA designs.Integrated online IV measurementFind out more from your EREMA specialistVACUREMA PLANT FEATURESIn practice, depending on input material quality andespecially with the VACUREMA systems ADVANCED andPRIME, individually increased IV values for the repelletscan be achieved by controlling throughput and extentof vacuum in use at the plant .Diagram: IV increaseaccording to VACUREMAtype and set plantthroughput performance;example based onVACUREMA model 1716(indicative).IV of finished PET repellet0.840.830.810.810.790.780.760.760.760.860.840.820.800.780.760.740.720.700.68IV800 kg/h 1000 kg/hnominal output1200 kg/hIV increase0.740.731400 kg/hincrease inoutput0.760.800.71IV values of repellets adjustable depending on throughput of plantExtremely convenient: IV values inreal timeAs standard a so-called “food contact control mode” canbe activated at a pushbutton on all VACUREMA plants:When activated, if sensitive “food grade” processingparameters are not within preset limits, the plant gives analarm and simultaneously switches its output to a ”techgrade” bypass.“Food contact” – operation mode:11VACUREMA INLINE SYSTEMSThe VACUREMA technologies are not only ideal for producing PET repellets. Also successfuland widely used so-called inline applications in which finished end products are produceddirect from PET bottle flake material input are available. The unique advantage of all“inline”-systems is its maximised direct value-adding by directly producing an end product,avoiding the detour of pelletising.For direct production of flat sheet . The sheet producedcomplies with FDA purity requirements and is thus suitablefor direct food contact packaging (see separate brochure)VACUREMA INLINE SHEET SYSTEMS VACUREMA INLINE STRAPPING SYSTEMSFor direct production of high strength strapping tapefrom 100% bottle flake. (see separate brochure)VACUREMA INLINE FIBRE SYSTEMSFor direct production of fibre from 100% bottle flake ormixtures of bottle flake-virgin material.For 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.atSubject to technical modifications. Printed 06/2009_E© EREMA Engineering Recycling Maschinen und Anlagen Ges.m.b.H.ModelVACUREMA 906VACUREMA 1007VACUREMA 1108VACUREMA 1109VACUREMA 1310 1)VACUREMA 1512VACUREMA 1514VACUREMA 1716VACUREMA 2018VACUREMA 2021Throughput performance (kg/h) depending on type of application,input material quality and desired IV value120 - 200150 - 300250 - 400300 - 500400 - 600550 - 800700 - 11001000 - 14001300 - 18001700 - 25001) VACUREMA PRIME available from type VACUREMA 1310 – smaller plant sizes on requestVACUREMA PET Extrusion Technologies –available plant sizesNotes