Process Control GmbH, a leading supplier of auxiliary equipment for the plastics processing industry

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CO2 saving processes in Extrusion plants - 
In-Line Recycling of PROCESS CONTROL 

In times of huge increases in energy costs everyone looks for saving each possible kilowatt-hour. Looking ahead to the future, with worldwide energy consumption increasing, further price rises can be expected making the situation even more critical.

Plastic extrusion companies in particular have substantial electricity running costs
One method of recycling production-caused film scrap is by “repelletizing”. One advantage of a repelletizing line is that it p
roduces an easy to handle bulk material (granulate). However, a negative aspect is that this process puts a large amount of thermal energy into the material. This can cause a chemical degeneration of the material resulting in a change of the melt-flow index (MFI). In many cases a re-stabilisation is required by the use of expensive additives. Another disadvantage is that this procedure devours enormous amounts of energy.
A typical repelletizing system consumes in total, for the whole recycling process (cutting, melting, granulating, cooling, transportation), approximately 1.75 kWh per kg of the plastic that is recycled. An example of the energy used in a typical situation is given below: With a total throughput of 900 kg/h, a recycling rate of 15 % and a machine running time of 24 h a day, 5 days a week and 48 weeks a year then approx. 1.360.000 kWh per year will be consumed. In Germany, for example, production of electricity creates CO2 emissions of approx. 130 g CO2 per kWh. Which means the electricity used in the repelletizing process shown above will produce approx. 177 tons of CO2 per year!!!  

The asr system itself is very uncomplicated in handling and start-up. It usually consists of an edge-trim transport system using a venturi system, a film scrap grinder and a refeed machine. The refeed machine, which is directly mounted on the extruder, compresses the ground material and feeds it to the extruder. By compressing a 5- to 7-times higher bulk density is achieved compared to loose fluff. Thereby pumping of the extruder is avoided.

To find out more about the asr system



The new ENERGYcut controls with frequency converter and self-adapting intelligent power control for a maximum of energy savings, installed at the pump frame. With this controls the main material will be feed with the max power. If there are difficult materials to convey, the convey power will be reduced to the absolute required minimum and in time without any convey request the energy consumption will go down to the lowest possible level. The line will be in this case still in stand by for accelerating speed up in case of a request.
With this method beside of the energy saving the noise level will be reduced significant.

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Guardian® Series 2 Gravimetric Batch Blenders

The all-new design of Guardian® Series 2 provides precise batch-to- batch dispensing and consistent homogenous blending. New standard features include off-the-shelf controls, color touch-screen, removable cartridge V-gate metering, segmented material hoppers, integral drain chute, and a “No Dead Zone” mixing chamber. Guardian® Series 2 may be configured with four-to-twelve ingredient hoppers, with each hopper capable of running 0-100% of the recipe with dispensing accuracy up to +/- 0.02%. Guardian® Series 2 is comprised of four models, including 1.25/2.5kg, 5kg, 12kg and 18/25kg, with throughput rates to over 5,000kg/h. Guardian® Series 2 blenders continue to set the standard for accuracy and blend homogeneity in each and every batch.

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