Difference between revisions of "Vacurema technology"
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[[File:VACUREMA Prime.jpg|thumbnail|Vacurema Prime Technology]] | [[File:VACUREMA Prime.jpg|thumbnail|Vacurema Prime Technology]] | ||
| − | [[Erema]]'s Vacurema systems offer modular solutions for different solutions for recycling of PET bottles. The patented process is designed for the recycling of post consumer PET bottle flakes, PET in-house waste and also PE-HD bottle flakes. Vacurema technology | + | [[Erema]]'s Vacurema systems offer modular solutions for different solutions for recycling of PET bottles. The patented process is designed for the recycling of post consumer PET bottle flakes, PET in-house waste and also PE-HD bottle flakes. Vacurema technology was first launched in 1998. |
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. | 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. | ||
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| − | ''' | + | '''Flexibility with input material''' |
Input materials with up to 1.5% moisture can be processed, no expensive pre-drying is necessary- Extruder degassing is not required either, meaning that a short extruder screw can be used and the thermal stress on the material is reduced as a result. | Input materials with up to 1.5% moisture can be processed, no expensive pre-drying is necessary- Extruder degassing is not required either, meaning that a short extruder screw can be used and the thermal stress on the material is reduced as a result. | ||
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 850kg/m³. | 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 850kg/m³. | ||
| + | |||
| + | '''Efficient 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. | ||
| + | Surface to volume ratio for flakes is 2.5 times higher than for pellets | ||
| + | * Bulleted list item | ||
'''Bottle flakes''' | '''Bottle flakes''' | ||
| − | |||
Pre-ground with 12 mm screen, average wall thickness approx. 0.1 to 0.4mm | Pre-ground with 12 mm screen, average wall thickness approx. 0.1 to 0.4mm | ||
| + | * Bulleted list item | ||
'''Pellets''' | '''Pellets''' | ||
| − | |||
Typical dimensions: diameter approx. 2.5mm x 3mm length or ball shap | Typical dimensions: diameter approx. 2.5mm x 3mm length or ball shap | ||
| − | ''' | + | '''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. | 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 in a stable process environment. This prevents any hydrolytic and oxidative decomposition of the melt in the extruder. | The patented pre-treatment at raised temperature and in high vacuum before the extrusion process removes moisture and migration materials from the feedstock 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 minimized dwell time. | The very short extruder screw without additional extruder degassing reduces the thermal stress on the material through minimized dwell time. | ||
| − | ''' | + | '''Large area ultrafine melt filtration''' |
The filter systems have very large active filter surfaces. This enables filtration with up to 32μm fineness at low pressure. The result is highly clean pellets. | The filter systems have very large active filter surfaces. This enables filtration with up to 32μm fineness at low pressure. The result is highly clean pellets. | ||
| − | ''' | + | '''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 costs of all systems on the market. | Electricity accounts for 38% of the costs of bottle-to-bottle recycling. Thanks to integrated ecoSAVE technology, 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-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. | 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. | ||
| − | ''' | + | '''Turnkey solutions''' |
Erema delivers turnkey systems with support from one contact for the entire recycling process: sorting – washing – decontamination – extrusion – quality control – end product. | Erema delivers turnkey systems with support from one contact for the entire recycling process: sorting – washing – decontamination – extrusion – quality control – end product. | ||
Revision as of 12:30, 9 February 2016
Vacurema
Erema's Vacurema systems offer modular solutions for different solutions for recycling of PET bottles. The patented process is designed for the recycling of post consumer PET bottle flakes, PET in-house waste and also PE-HD bottle flakes. Vacurema technology was first launched in 1998.
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
In this process, food contact compliant decontamination takes place before the extrusion process. The patented pre-treatment of PET flakes 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. Thanks to the vacuum treatment, stable IV values can be achieved even in the case of varying moisture levels and different IV values in the input material.
Flexibility with input material
Input materials with up to 1.5% moisture can be processed, no expensive pre-drying is necessary- Extruder degassing is not required either, meaning that a short extruder screw can be used and the thermal stress on the material is reduced as a result. 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 850kg/m³.
Efficient 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. Surface to volume ratio for flakes is 2.5 times higher than for pellets
- Bulleted list item
Bottle flakes Pre-ground with 12 mm screen, average wall thickness approx. 0.1 to 0.4mm
- Bulleted list item
Pellets Typical dimensions: diameter approx. 2.5mm x 3mm length or ball shap
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 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 minimized dwell time.
Large area ultrafine melt filtration
The filter systems have very large active filter surfaces. This enables filtration with up to 32μm fineness at low pressure. The result is highly clean pellets.
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 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-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.
Turnkey solutions
Erema delivers turnkey systems with support from one contact for the entire recycling process: sorting – washing – decontamination – extrusion – quality control – end product.
Three application fields
Bottle-to-Bottle
Vacurema Prime PET extrusion system features two crystallisation dryers operating in batch mode. 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, the company can offer its Vacurema technology also in combination with an SSP solution from Polymetrix.
