There is a way which takes you to your target faster. Without detours. A way which enables you to save energy and space, increase your productivity and reduce your costs. It is the direct way: the VACUREMA® Inline solution. With this solution you go from post-consumer PET flakes directly to finished thermoforming sheet or bottle preforms, to finished strapping or monofilaments. In a single process step.
We realise these direct benefits for you by combining the highly efficient VACUREMA® system with the appropriate downstream production line. Leading technologies which merge seamlessly. For more efficiency and cost-effectiveness at your production facility.
Better solution. Better direct.
VACUREMA® Inline Applications.
From flakes to the end product in a single process step. The key components of the system include a vacuum reactor which is connected directly to a single-screw extruder. Thanks to the ingenious function of the mixers in the vacuum reactor they feature three ultra-efficient function zones which interact perfectly with each other to decontaminate and predry the PET material perfectly already BEFORE extrusion:
Zone 1 is responsible for the removal of the outer moisture of the PET flakes. The amorphous, washed flakes which enter Zone 1 via a vacuum sluice, still have extremely varying external moisture (between 0.5 and 1%). This is eliminated at around 20°C under vacuum through the reduced vaporisation point (the inner moisture here is still constant at around 0.3%).
In zone 2 the temperature rises from 20°C to 190°C. Thanks to the constantly rising temperature the polymer structure opens up and the process for the removal of the migration substances and the internal moisture from the flakes begins.
Zone 3: the process of flake decontamination and removal process unfolds with full effect. The material moves layer by layer in the direction of the single-screw extruder during the exactly defined residence time. With very low residual moisture of under 0.05% the clean, perfectly prepared material enters the intake zone of the extruder.
This material transfer takes place under high vacuum. As a result no additional degassing ports are required on the extruder itself. This means that VACUREMA® technology drastically reduces the length of the extruder, reduces its energy consumption, improves the colour values (b value) of the processed material and keeps AA values to a very low level. Moreover, the strong homogenisation performance of the extruder plays a significant part in turning the different input IV values into a stable output IV value.
In the downstream high-performance fine filter the material is filtered with a 32 µm mesh screen width. The filter system is equipped with a patented fully automatic self-cleaning system that enables long filter service life. The melt is now ready and can be transferred directly to the downstream unit. This is where the desired end products – thermoforming sheet, preforms, strapping or fibres – are produced inline without the detour of pelletising. As an option, amorphous or crystalline pellets can also be produced instead of the end products.