KraussMaffei’s EdelweissCompounding technology guarantees high recombination quality even at high production rates, which can reach several tons per hour. This was made possible by the fact that KraussMaffei once again optimized and supplemented the already known technology. Distinctive features of the modernized line are the new module of our own design CutterCompactor, intended for preliminary processing of any consumer waste, as well as a 2-stage module consisting of two series-connected twin-screw extruders for melt preparation and compounding.
“The updated EdelweissCompounding production line is now available for tests for compliance with customer requirements in our experimental workshop. In addition to acquiring new functionalities, it is now a turnkey installation, ”says Karl-Philip Pepel, Head of Extrusion Technology at KraussMaffei. Thanks to the large capital investment, KraussMaffei is expanding its possibilities for customer-specific testing or for its own testing of recycling and recombination technologies. A few months ago, a state-of-the-art industrial recombining line was installed in the experimental workshop of the Hanover plant.
New combination of extruders
The new EdelweissCompounding line consists of two twin-screw extruders ZE 65 Blue Power and is designed for a maximum capacity of 2000 kg / h. Since it was previously common to use one single screw and one twin screw extruder, the use of two twin screw extruders is new. The advantages of this solution speak for themselves: high degassing efficiency, odor removal, perfect dispersion mixing, gentle melt processing – all at high productivity. At the first stage, the ZE 65 Blue Power twin-screw extruder provides degassing of the incoming raw material, which may contain up to 10% moisture. At the same time, the associated odorous substances are removed, which is very important when processing consumer waste. By degassing with the addition of a separating agent such as water, nitrogen or carbon dioxide, odor can be minimized. “In addition, the twin-screw extruder
the first stage ensures optimal homogenization of the raw material, which is often not homogeneous, ”underlines the advantage of the new extruder combination Karl-Filip Pepel
In the second twin-screw extruder, into which the melt enters through the melt supply line, the compounding process takes place.
Karl-Philip Pepel explains: “The twin-screw extruder can be used for any technological task without any problems, be it filling, reinforcing, painting or adding additives. For this, our extruders are equipped with all the necessary additional units for dosing granules, powders, fibers and liquids. ” In addition to weighers for feeding various materials, the equipment of twin screw extruders includes related equipment such as fine melt filters, melt pumps and a BKG® pelletizer from Nordson Corporation. CutterCompactor Module Another innovation in the Edelweiss product line is the CutterCompactor module, which is the first to appear in the KraussMaffei product line. The CutterCompactor works in standalone mode, and the resulting agglomerate is unloaded onto a weighing belt weigher. “Thus, we use weighing dosing with an accuracy of 99.8%,” says Karl-Philip Pepel, emphasizing the fundamental difference from the previously used volumetric dosing. This eliminates dosing deviations that arise, for example, when using light and bulky raw materials such as films or fibers. Now all LDPE, HDPE, PP or PS fractions recovered from consumer waste can be processed into a high-quality recompound without any problems, which is used in injection molding and extrusion as a replacement for the primary material.
An important feature of the EdelweissCompounding production line installed in the pilot plant is its full integration into a completely independent turnkey system. The main advantages of such a solution for the client are the possibility of installing the line without any preparation, ease of commissioning, flexibility of use in the process.
Such a line is designed in such a way that it can be installed in any workshop. The presence of different levels or special room configuration is not required, since the line has a well-thought-out design and contains everything necessary for the recombining process. After delivery, you just need to connect the equipment to local communications, providing the supply of electricity, water and compressed air, and you can immediately start production. When the production site is changed, the entire line is transported and at the new location is immediately ready for processing materials.
Competence combined with experience
“Interested customers can carry out industrial scale trials with the new state-of-the-art EdelweissCompounding line in our pilot plant and see the benefits of a complete production line concept in a modular fashion,” says Karl-Philip Pepel, inviting customers to collaborate on new material development projects. The combination of mechanical engineering expertise with extensive formulation experience specifically for the production of high-quality compounds and recompounds from consumer and industrial waste makes the Hanover-based company the ideal partner for upcycling projects (waste recycling
polymers to obtain plastics with the properties of primary raw materials). Availability of a small analytical laboratory as well as a casting machine
under pressure, intended for the production of product samples from recompounds, complete the offer.