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INTAREMA® TVEplus®

Filtration, homogenisation and degassing at the highest level

 

The patented extruder system INTAREMA® TVEplus® sets new standards in the recycling of materials that are difficult to process such as heavily printed films and/or very moist materials. This is made possible through ultrafine filtration, thorough melt homogenisation and high-performance degassing in a single step.

The proven basic principle of TVEplus® technology: melt filtration takes place upstream of extruder degassing. As a result, end products can be produced with the best quality and the highest possible recyclate content.

Technical benefits

 
  • Enhanced material intake, greater flexibility and higher throughput rates thanks to Counter Current technology
  • Optimised triple degassing with the preconditioning unit, optimum screw design and extruder degassing ensure highly effective degassing of the filtered melt
  • Reduced shearing before the filter improves filter performance
  • Greater homogenisation efficiency downstream of filtration and upstream of degassing enhances the subsequent degassing performance and improves the characteristics of the melt
  • Innovative, patented additional technologies for the Preconditioning Unit – DD system and Air Flush module (optional) widen the scope of application

Economic benefits

 
  • High-quality end product even with materials that are difficult to process such as heavily printed films and/or very moist materials; end products can contain a considerably higher share of recycled pellets
  • Extremely easy to use thanks to the Smart Start principle
  • ecoSAVE® reduces energy consumption by up to 12 % as well as production costs and CO2 emissions as a result
  • Much higher outputs with the same screw diameter compared to conventional degassing extruders 
  • Compact, space-saving design 
 

IMPRESSIONS

INTAREMA® TVEplus®

 
 

How it works

INTAREMA® TVEplus®

1 2 3 4 5 6 7 8
  1. Charging :

    Feeding is automatic according to customer requirements.

  2. Preconditioning Unit:

    In the Preconditioning Unit the material is cut, mixed, heated, dried, pre-compacted and buffered. Next, the tangentially connected extruder is filled continuously with hot, pre-compacted material.

    The innovative Counter Current technology enables optimised intake action across an extended temperature range.

  3. Extruder screw :

    In the extruder screw the material is plasticised and degassed in reverse. 

  4. Fully-automatic self-cleaning filter:

    At the end of the plasticising zone the melt is directed out of the extruder, cleaned in the fully automatic, self-cleaning filter and returned to the extruder again.

  5. final homogenising of the melt :

    The final homogenisation of the melt takes place after the melt filter.

  6. Degassing zone:

    The filtered and homogenised material is degassed in the subsequent degassing zone.

  7. Discharge zone:

    Following this, and with the help of the discharge zone, the melt is conveyed to the respective tool (8) (e.g. pelletiser) at extremely low pressure.

  8. Tools:

    Following this, and with the help of the discharge zone (7), the melt is conveyed to the respective tool (e.g. pelletiser) at extremely low pressure.

 

Feeding (1) is automatic according to customer requirements. In the Preconditioning Unit (2) the material is cut, mixed, heated, dried, pre-compacted and buffered. Next, the tangentially connected extruder is filled continuously with hot, pre-compacted material. The innovative Counter Current technology enables optimised intake action across an extended temperature range.

In the extruder screw (3) the material is plasticised and degassed in reverse. At the end of the plasticising zone the melt is directed out of the extruder, cleaned in the fully automatic, self-cleaning filter (4) and returned to the extruder again. The final homogenisation of the melt (5) takes place after the melt filter. In the subsequent degassing zone (6) the filtered and homogenised material is degassed. Following this, and with the help of the discharge zone (7), the melt is conveyed to the respective tool (8) (e.g. pelletiser) at extremely low pressure.

 

cuts

homogenises

heats

dries

compacts

buffers

doses

 

OPTIMISED TRIPLE DEGASSING

  • Initial degassing in the EREMA preconditioning unit takes place through preheating and pre-drying the material
  • The optimum screw design - tuned to the material to be processed - enables reverse degassing in the preconditioning unit, thus relieving the degassing zone of the extruder
  • Gas inclusions in the melt are removed in the extruder degassing zone
  • Only thoroughly melted, filtered and homogenised material can pass the degassing zone of the extruder

HIGH PERFORMANCE FILTERING WITH SOFT MELTING.

The melting procedure takes place with minimum shearing effect. This prevents any further size reduction of disturbing contaminants prior to filtration and enhances filtration efficiency.

A comparison test with washed post-consumer films (film sample with 100% recyclate), filtered with the EREMA laser filter (110 µm), confirms this increased filtration performance thanks to minimal shearing.

GROUNDBREAKING INNOVATION

Counter Current technology developed by EREMA changes the direction of rotation inside the preconditioning unit: the plastic material thus moves in the opposite direction to that of the extruder screw. A small change with a big impact: the relative speed of the material in the intake zone, i.e. when passing from the preconditioning unit to the extruder, accelerates so that the extruder acts in the same way as a sharp cutting edge which literally "slices up" the plastic.

 

As a result the extruder handles more material in a shorter time. Thanks to the enhanced material intake plastic can be processed even at lower temperatures at a high throughput - meaning higher productivity, flexibility and operational reliability

INTAREMA® TVEplus® IN ONE:

 
counter current
 
 

Counter Current technology

  • Highest process stability through improved material intake ensures constantly high output over a considerably broader temperature range
  • Higher flexibility and operational reliability with a variety of materials
  • Increased throughputs with the same plant size for more productivity
smart start
 
 

Smart Start technology

  • Remarkably easy to operate thanks to logical, clearly structured and simplified handling and ultramodern, ergonomic touch screen display 
  • Fewer buttons, more user-friendliness – thanks to high degree of automation including extensive control packages 
  • The right recipe for every application – saved processing parameters can be loaded easily and conveniently from the recipe management system at the push of a button
eco save
 
 

ecoSAVE®  technology

  • Lower specific energy requirements thanks to a complete package featuring design and process engineering measures, such as the new direct-drive extruder screw 
  • Lower production costs through optimised control technology and high-quality, energy-efficient components such as high-performance motors 
  • Additionally, the practical energy display on your operating panel gives you a constant overview of energy consumption at all times, thus enabling you to take specific measures to optimise consumption 
  • Reduced CO2 emissions – an important contribution to environmental protection

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DD / Air Flush Module
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