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Recycling of plastics: Cost-effective & innovative solutions to meet the industry’s challenges

People all over the world are becoming more aware of sustainability and the need to protect the environment is growing. As a result, the demand for better recycling of plastics grows.

A major challenge for recycling companies is processing the sheer variety of plastics. These range from household packaging to industrial products. Printed films and moist materials are especially problematic and often not very cost-effective.

In this article, we look at these challenges. We also demonstrate how innovative technologies and machines make the recycling of plastics more profitable.

What are the most frequent challenges in the recycling of plastics?

Printed materials

Printing inks on films make the recycling of plastics difficult. On the one hand, printed materials can contaminate machine parts. On the other hand, the different color components ensure that the granulate does not end up with a unicolor.
This means that printed materials cause:

  • Lower quality recyclates in terms of the optical and technical properties of the end product
  • More complex manufacturing process
  • Additional costs due to the extra work
  • Downcycling replacing the recycling of plastics

Innovations enable more sustainable recycling of printed plastic films. Advanced technologies are needed that specialize in the efficient removal of printing inks.

Green printed plastic film

Input materials with different moisture contents

Moisture has a negative impact on mechanical properties, which causes problems during processing. The reason for this is that it influences the melting point and viscosity. All this leads to:

  • A low-quality end product
  • Increased energy consumption
  • Corrosion of machine components
  • Formation of mold, bacteria and fungi

That is why effective drying processes in recycling plants are crucial. Removing moisture not only improves the quality of the recycled material. The processes in the recycling of plastics also become more efficient.

Colorful shreds of plastic film

Wide range of recyclable plastics

There are numerous types of plastic such as PE, PP, PS, PC and PA. Each type of plastic has unique chemical and physical properties that require processes specific to each material.

Recycling machines need to be able to meet the necessary temperature specifications for each type of plastic.

The same applies to the different melting properties. Melt-specific extrusion parameters might be needed to ensure the high quality of the recycling of plastics.

Colorful film shreds

Technological solutions based on READYMAC and EREMA technology

The answer to complex problems is research and innovation. Solutions that are sustainable and cost-effective are particularly important for recycling companies.

For the challenges mentioned above, there are now technological innovations that meet all the requirements.

Description of READYMAC technology

Improved melt filtration for printed materials

Since its inception, EREMA has carried out intensive research on the recycling of plastics. One of the innovations the company invented is the multipurpose screw with patented TVE technology. This ensures improved melt filtration upstream of extruder degassing.

This configuration removes impurities extremely efficiently. The result is high-quality recyclate, which overcomes problems with filtering and sorting printed materials.

Preconditioning Unit (PCU) for improved drying

A preconditioning unit (PCU) shreds, mixes, heats, dries and predensifies the materials to remove moisture.

A PCU keeps the extruder constantly filled, improves the quality of the recycled material and uses less energy. It also minimizes the risk of corrosion and eliminates hygiene problems.

This technology can be found in the UMAC READYMAC 1109 TVE, for example.

Multipurpose screw for the recycling of various plastics

The innovative multipurpose screw enables the reliable recycling of PE, PP, PS, PC and PA. It is also used in the READYMAC 1109 TVE. This is possible thanks to the melt-specific extrusion parameters and temperatures.

Environmental and cost-effective advantages due to more effective recycling of plastics

With its innovative technology, READYMAC is a good example of how recycling of plastics provides more than just ecological benefits. It can also be very profitable:

Process efficiency and throughput: Due to the consistent and efficient process, it is easy to process high volumes of plastic waste.

Lower operating costs: The READYMAC, for example, is very flexible when it comes to processing different types of plastic. It also removes contaminants efficiently. This significantly reduces operating costs for recycling companies. The machine also minimizes the need for expensive additional equipment and manual sorting processes.

Cost-efficient technology: The READYMAC 1109 TVE is a cost-effective solution for the recycling of plastics at a fixed price. This makes it possible to realize a return on investment quickly and to operate economically.

High-quality recyclates: The READYMAC uses patented EREMA technology to produce materials of the highest quality. This increases competitiveness in the market. It also meets the increasing demand for environmentally friendly and sustainable materials in various industries.

Minimizing waste and losses: Processing printed materials and removing ink reduces the amount of plastic waste that cannot be recycled. This leads to a better yield of high-quality recyclate and reduces losses.

Investing in innovative solutions for the recycling of plastics pays dividends

Major challenges for recycling companies across the world are printed materials, input materials with different moisture levels, and the sheer range of recyclable plastics. Thanks to many years of research, innovative recycling machines are now on the market. Their good price-performance ratio makes advanced technologies accessible to everyone. This is more important than ever in times of climate change and environmental pollution. Better recycling solutions minimize plastic waste.

With the help of

  • Improved melt filtration for printed materials,
  • Preconditioning Units (PCUs) for improved drying, and
  • Multipurpose screws for the recycling of various plastics

reliable processing is ensured even with challenging starting materials.

The READYMAC 1109 TVE can be purchased for the attractive fixed price of € 375,000 and is available at any time. Are you interested and would you like to find out more? Then contact us.

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