Unlike conventional bottle-to-bottle processes, with VACUREMA® technology, decontamination takes place already at the PET flake stage – and not until after they are in pellet form. As a result you are faster in obtaining a top quality, consistent, ultra-clean, food contact approved end product.
Moreover, it gives you a high degree of flexibility as a result, because the technology evens out any differing moisture and IV values in the input material.
Thanks to the pretreatment of the PET flakes at high temperature and vacuum, moisture and migration substances are removed from the material effectively and in a stable process environment already prior to extrusion. This prevents any hydrolytic and oxidative decomposition of the melt in the extruder. A clear bonus for the quality of your end product.
Thanks to highly efficient decontamination the system fulfils and also far exceeds all well-known minimum purity requirements for direct food contact already after the batch process.
The system achieves stable IV values despite varying moisture levels and different IV values in the input material. The pretreatment in the two crystallisation dryers is essential for this IV stability. This takes place under vacuum and makes for excellent homogenisation of the material.
Melting under vacuum and an overall very short residence time of the PET material inside the system – thanks to this particularly sensitive processing, VACUREMA® gives you recycled pellets with top and stable colour results – with a shape and appearance on a par with virgin material!
Thanks to the efficient ultrafine filtration, the smallest of contaminants such as aluminium and steel particles are removed from the PET melt highly effectively and in a material-friendly way.
Two parallel vacuum crystallisation dryers are filled with amorphous, washed PET flakes. The crystallisation dryers work in proper 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 vacuum and at increased temperature. The decontamination requirements specified by authorities and brand owners are fulfilled through the adjustable batch times.
The two identical crystallisation dryers are situated immediately upstream of the continuously operating vacuum reactor. The IV increase of the PET flakes takes place inside the reactor through solid-phase polycondensation which takes it to the required level. The material is melted under vacuum in the directly connected extrusion system.
The benefits of the VACUREMA® extruder: robust single screw technology and compact design for minimum thermal material stress.