Vacurema technology: Difference between revisions

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 '''* 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
+'''* Melting under vacuum'''
 The patented pre-treatment at raised temperature and in high
 vacuum before the extrusion process removes moisture and
@@ Line 22: / Line 27: @@
 a stable process environment. This prevents any hydrolytic and
 oxidative decomposition of the melt in the extruder.
-'''Low thermal stress'''
+* '''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'''
+* '''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
-®
+Thanks to their compact design, VACUREMA  systems require much less space than other systems.
-  systems require
-much less space than other systems.
+* '''Minimum production costs with ecoSAVE'''
-Minimum production costs with ecoSAVE
-®
+Electricity accounts for 38% of the costs of bottle-to-bottle recycling. Thanks to integrated ecoSAVE technology, the lowest production
-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
+* '''Smart Start principle'''
-The plant‘s software-based process control system gives you
+The plant‘s software-based process control system gives you extremely easy and reliable operation and premium user-friendliness 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.
-extremely easy and reliable operation and premium user-friend
+* '''Turnkey solutions'''
--
+Erema delivers turnkey systems with support from one contact for the entire recycling process: sorting – washing – decontamination – extrusion – quality control – end product.
-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
+'''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.
+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.
-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
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