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

How it works

INTAREMA^® TVEplus^®

1 2 3 4 5 6 7 8

Charging :
Feeding is automatic according to customer requirements.
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.
Extruder screw :
In the extruder screw the material is plasticised and degassed in reverse.
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.
final homogenising of the melt :
The final homogenisation of the melt takes place after the melt filter.
Degassing zone:
The filtered and homogenised material is degassed in the subsequent degassing zone.
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.
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.

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