Vacurema technology: Difference between revisions

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 Erema claims that there are currently more than 150 Vacurema systems in use around the world, producing high-quality pellets and end products with an overall capacity of over 1 million tonnes.
+=== Basic principles ===
+'''* Flexibility with input material'''
+Depending on the end application the system processes PET bottle flakes, ground amorphous skeleton waste/edge trim and virgin material (also in mixtures), i.e. bulk densities of 250 to 850 kg/m³.
+'''* Food contact compliant decontamination'''
+Thanks to the patented pre-treatment of PET flakes, IV increase and decontamination are fast, reliable and energy-saving. This means that FDA quality (among other things) can be ensured
+for the end products produced.
+'''* IV stability through vacuum treatment'''
+Despite varying moisture levels and different IV values in the input material, stable IV values are achieved through the patented pre-treatment method. This means, therefore, that input materials with higher material moisture levels can also be recycled.
+'''*''' Melting under vacuum
+The patented pre-treatment at raised temperature and in high
+vacuum before the extrusion process removes moisture and
+migration materials from the feedstock very effectively and in
+a stable process environment. This prevents any hydrolytic and
+oxidative decomposition of the melt in the extruder.
+'''Low thermal stress'''
+The very short extruder screw without additional extruder
+degassing reduces the thermal stress on the material through
+minimised dwell time.
+'''Large area ultrafine melt filtration'''
+EREMA filter systems have very large active filter surfaces. This
+enables filtration with up to 32 μm fineness at low pressure.
+The result is highly clean pellets.
+* '''Compact design'''
+Thanks to their compact design, VACUREMA
+®
+ systems require
+much less space than other systems.
+Minimum production costs with ecoSAVE
+®
+Electricity accounts for 38
+% of the costs of bottle-to-bottle
+recycling. Thanks to integrated ecoSAVE
+®
+ technology,
+VACUREMA
+®
+ systems stand out through the lowest production
+costs of all systems on the market.
+Smart Start principle
+The plant‘s software-based process control system gives you
+extremely easy and reliable operation and premium user-friend
+-
+liness including automatic start-up at the press of a button,
+fully automatic continuous operation, permanent monitoring
+for direct food contact (FCC) and the storage of all relevant
+process parameters.
+Turnkey solutions
+We deliver you turnkey systems with competent support from
+one contact for the entire recycling process: sorting – washing
+– decontamination – extrusion – quality control – end product.
 === Three application fields ===
+Bottle-to-Bottle
+rPET pellets which not only fulfil but exceed all current minimum requirements with regard to direct food contact for PET packaging solutions: that is the end product in bottle-to-bottle recycling with VACUREMA Prime technology. This high-end PET extrusion system features two crystallisation dryers operating in batch mode. A compact, space-saving all-in-one solution which achieves IV increases and a remarkable cleaning effect. As the user you are flexible at all times and can react quickly to current market requirements: whether it‘s decontaminated, pre-dried and crystallised rPET flakes or high-quality, melt-filtered rPET pellets – products produced using VACUREMA Prime technology fulfil the respective criteria of the FDA, EFSA and many major brand owners.
+If IV values of > 0.9 dl/g or very high throughputs (> 2500 kg/h)
+are required, EREMA can offer VACUREMA technology also in combination with an SSP solution from Polymetrix.
+Approved for direct food contact
+Operating mode 1
+% rPET pellets
+Operating mode 2
+% rPET flakes
+Operating mode 3
+% rPET flakes
+and rPET pellets
+(simultaneous)
+Bühler Thermal Processes AG
+a former Bühler Group Company
+Brand
+Owner
+appr
+O
+ved
+Technical benefits
+•
+Minimum thermal stress and
+minimum discoloration
+ thanks to
+single energy input, preheated
+material and shortened extruder
+length
+•
+Batch operation
+ – guaranteed,
+adjustable dwell times for every
+single flake in the two crystallisation
+dryers ensure maximum cleaning
+efficiency
+•
+Highly efficient decontamination
+fulfils and also far exceeds all
+well-known minimum purity
+requirements for direct food
+contact already after the batch
+process
+•
+FDA approved
+ (EFSA approval
+requested via customers and
+obtained), certification from major
+brand owners
+•
+Large area ultrafine melt filtration
+•
+Stable PET melt processing
+ with
+IV increase of up to 6 to 10
+%
+•
+AA (acetaldehyde) content in
+pellets less than 1 ppm –
+ possible
+in combination with optional pellet
+flusher (no flusher required in the
+case of pre-drying before preform
+production)
+•
+Possible to process flakes from
+cooking oil bottles
+How it works
+Two parallel vacuum crystallisation dryers
+are each filled
+with amorphous, washed PET flakes via a vacuum lock. The
+crystallisation dryers operate in what is referred to as batch
+mode. The exceptionally high level of purity of the rPET that is
+produced is achieved by an
+exactly defined and guaranteed
+minimum treatment time for every single thin-walled
+PET flake
+in high vacuum and at high temperature.
+Purity and IV requirements placed on the end product
+(rPET pellets) can be adapted individually by selecting
+appropriate batch times.
+The two identical crystallisation dryers are placed
+immediately upstream of a continuous VACUREMA
+®
+Basic extrusion system.
+Economic benefits
+•
+rPET pellets identical in
+consistency and appearance to
+virgin material,
+choice of
+amorphous or crystalline
+•
+Low production costs
+ through
+specific energy consumption of
+.32 to 0.36 kWh/kg
+•
+Total production costs for rPET
+from PET flake only approx.
+.10 euros per kg of finished
+BTB pellets
+•
+Compact, space-saving design
+(feeding system not shown)
+Feeding
+(discontinuous)
+PET Flake
+PET Flake
+Vacuum lock
+Vacuum lock
+Vacuum pump
+Vacuum
+pre-treatment
+unit
+(discontinuous)
+Vacuum reactor,
+continuous
+operation
+VACUREMA
+®
+Basic
+extrusion
+system
+μ
+m high-performance filter
+with large active filter area
+Page 8 - 9