Regis Machinery News

High Quality packaging film line features KREYENBORG filtration

High quality packaging film is now manufactured from recycled PET on a new line at Sharp Interpack’s Bridgwater, Somerset site. The new line allows up to 100% recycled PET sheet to be produced direct from hot caustic wash plants.

The operation is now further enhanced with a Power Back-Flush (V-type) screen changer from Kreyenborg GmbH- Germany that gives highly efficient cleaning of the screen packs without additional pressure from the extruder.

The system is particularly effective when processing especially high portions of recycled material with a high pollution degree such as PET bottle flakes.  The new line at Sharp Interpack has a capacity of 1.500 kg/h, using 100% recycled PET.
The feedstock, originating from consumer waste is pre-cleaned in a washing line and then directly extruded removing harmful substances from the plastic. The process is covered by robust PIRA certification and meets all EU requirements. A key line component for the processing of the recycled polymer is the melt filter. In this extrusion line  - a Kryenborg Power Back – Flush (V-type) screen changer that automatically flushes filter screens independently of the extruder for interruption-free, constant pressure extrusion.
With each back-flush a constant quantity of material is discharged, so that in comparison to other systems, the material losses are very low and the screen life long. 
The growing use of recycled polymers are required to meet strict EU regulations on plastics destined for direct food contact so now, more than ever, there is a need to screen out contaminants.
In the field of plastics extrusion any kind of contamination in the melting process is unacceptable not only affecting the quality of the product but also impeding the operating process. Sharpak lead the way in the use of recycled materials and was the first manufacturer to introduce recycled PET from post consumer waste into its soft fruit punnets and is now well ahead in its development of 100% r-PET.
www.sharpinterpack.com 

KREYENBORG Trial Facilities
For customers wishing to see a demonstration of a KREYENBORG screen changer in the KREYENBORG trial facility in Muenster, Germany please contact UK agents Regis Machinery www.regismachinery.co.uk
Video of trial facilities

Kreyenborg Trial Facilities from Regis on Vimeo.

Worlds Largest Screen Changers

Not less than three! gigantic melt filters now have left the plant of the Kreyenborg GmbH in Münster. Each of these systems of the new type series Poly presents the biggest screen changer which has ever been constructed. These giants have been designed for the use in world-scale polymerisation lines instead of conventional candle filters. With a maximum throughput of up to 45.000 kg/h, depending on material, viscosity and filter fineness, these machines move into completely new dimensions.

The latest screen changers of the type Poly are to be recognized already by few characteristics. Contrary to most of the conventional screen changers, the housings are designed horizontally, so that the individual pistons are arranged side by side and not one upon the other. Every piston disposes of two opposed screen cavities. Screen changers with two or four pistons are available, whereas the version with four pistons shows a considerably better process pressure constancy. As usual with the screen changers, a breaker plate and the stainless steel wire-cloth screen pack are arranged within the oval screen cavities. Additionally, the machines of the Poly type series are equipped with special screen retainers. These screen retainers arrange for an always tight fit of the screen packs and fluidic optimisation. Furthermore, they reduce the melt volume during screen change as well as the already very low residence time of the Polymer in the filter.


Kreyenborg, being world market- and technology leader for screen changers, has put its complete experience into the development of the new screen changers for polymerisation. It has been managed to design a machine which offers the user essential economic advantages compared to conventional filter systems in polymerisation lines. Especially the cleaning of the filters is less complex and more favourable in price. Owing to the use of inexpensive flat screens all habitual advantages of a screen changer – like the always continuous production and the easy handling – are achieved. Thus the machines of the type Poly, supplied by Kreyenborg, are the first adequate screen changers for world-scale polymerisation lines.

The biggest version is the Poly 6000x4, which has a total filtration area of 24,000 cm², resulting from 6,000 cm² in each of the four pistons. Depending on material and viscosity the throughput amounts to up to 45,000 kg/h. The three machines of this size, which have been delivered now, will be applied with PET production in the MTR®-process of Uhde Inventa-Fischer. Two filters have been delivered to Indorama in Alabama USA , the third screen changer has been shipped to Alco-Naphta LLC in Kaliningrad Russia. When the first screen changer will be brought on line in the course of next year, the new Kreyenborg system may demonstrate its efficiency.

FOAMALITE Install Infra-red Dryer System

REGIS Managing Director David Bargery says that that ‘we have enjoyed strong interest in the complete range from the Kreyenborg Group. Some recent project highlights include delivery of a Kreyenborg  Infra-red dryer to Irish sheet producer FOAMALITE (www.foamalite.ie)

We have delivered an energy efficient infra-red drum for the Crystallizing and drying of PET flakes that is installed in a new multi million Euro installation of a complete sheet extrusion line at Ireland’s specialist sheet extruder FOAMALITE Loch Gowna site. Kreyenborg Infra red drying technology is widely acknowledged as the leading system for the rapid crystallizing and drying of PET. Not only for virgin PET
pellets, but also for a variety of mixes through to 100% regrind sheet.

For further details visit www.kreyenborg.com

View the 3D Video animation of the KREYENBORG IR Dryer Click Screen below

KREYENBORG Bulk Mixers for HDPE Bottle Flake Recycling

Greenstar WES of Wilton in the North East of England, has installed Kreyenborg bulk mixers in its first food-grade bottle-to-bottle HDPE recycling plant, following great success of previous installations. James Donaldson, WES Managing Director, said: “Homogenous material mix ensures optimum output and end product quality: all part of the plan to make first class feedstock with this energy saving facility.” A ready supply of bottle scrap is ensured by Greenstar’s nationwide collection service. “The addition of the food-grade HDPE plant will bring staff up to 75,” said Donaldson. The purchase is part of a multi million investment by parent company Greenstar, in the new bottle-to-bottle facility.

For further details please contact KREYENBORG UK Agents Regis Machinery (Sales) Ltd www.regismachinery.co.uk

Greenstar WES Website www.thewesgroup.co.uk

Regis Machinery are UK Agents for the KREYENBORG Group.www.kreyenborg.com Specialist manufacturers of equipment for the global compounding, masterbatch and extrusion recycling industries.

 Light-weight bulk material such as film flakes, fibers, hollow part ground stock, non-woven flakes, foams etc. quickly tend to bridge during the discharge.
Therefore the KREYENBORG Special Silos are an important component of a lot of plastics recycling lines following the size reduction for the intermediate storage and for the dosed input into the following extrusion, agglomeration, etc.

Replacement of Extruder Control at A. Schulman compounding plant

Schulman identified that although their twin- screw extruder was, in hardware terms, relatively new (built 10 tears ago), the control system was rapidly becoming outdated. The original control system did not offer the reliability, performance and features necessary to operate in todays competitive marketplace within the Masterbatch industry.

(Naturally capacity and performance of all PC’s and plcs have improved exponentially since this line was originally conceived – the world has progressed from computers with MS-DOS through to the world today with PC’s with ever increasing speed and huge memory capacity plus of course, the Internet)
The first Schulman complete extrusion line project which we finished last year, was to replace an old instrument based panel on a Farrel compounding system producing (4) tonnes per hour of masterbatch. As soon as that control system was in place the feedback from ALL of the line operators was extremely positive.

They really appreciated the ease of operation and the logical interface, which was provided by a single Siemens operator panel (HMI) controlling every single aspect of the complete line from extruder heating zones, through to screen changer and underwater pelletizer. Schulman were keen to replicate the success of the BSG ONE operator interface and decided to install a complete extruder control system for one of their twin screw extruders. This control system was retrofitted onto the twin screw extruder on schedule within the two week summer shutdown. BSG Engineers provided installation and commissioning support, with all functions being tested and I/O check (Inputs and Outputs) completed before the complete new operator control was handed over to the production team.

More details and video online of this CASE STUDY at  www.BSGcontrols.com

The new BSG One Control features the latest SIEMENS S7 plc hardware which offers a range of benefits including faster data processing, support for Open communications via Profibus, and built in 24 hour remote assistance support from BSG CONTROLS via modem link.

To view the video Case Study Click on VIDEO BELOW (Browser requires Adobe Flash Plug in www.adobe.com/flash



CONTACT REGIS MACHINERY (SALES) Ltd for more information www.regismachinery.co.uk

AURORA install compounding line with backflush filtration

 
United Kingdom based specialist compounder, AURORA Manufacturing, have installed a new Compounding line including completely automated backflush KREYENBORG screen changer, BKG Pelletizing system and BSG ONE extrusion line control. The Leigh, Lancashire based compounder and recycler is using the backflush screen changer to ensure that high quality PP Compounds are produced efficiently with no need for the operator  to make frequent screen exchange. AURORA feed the line with PP Flake from a variety of post industrial production scrap, the feed material can at times contain the metal threaded bushes from injection moulded parts. Previously with a  conventional lantern ‘slide plate’ type screen changer these metal parts can lead to an extremely short screen life, with the operator having to frequently exchange screens. The new Kreyenborg screen changer is completely automated and reacts to varying levels of contamination. The differential pressure is monitored, and once the pressure reaches a pre-defined level, the system initiates the automatic backflush process – without the need for an operator to attend to the line. The backflush process automatically cleans the screen packs and ejects the dirt particles out of the screen changer housing. An excellent demonstration of this backflushing process can be seen in the 3D Video animation below.
As part of the new compounding line project for AURORA REGIS MACHINERY also supplied a complete BSG ONE extrusion line control system (www.bsgcontrols.com) that takes care of every aspect of the 90mm twin screw compounding line control. From the control of the screw speed and heating zones, to the automatic start-up process of the complete line (Including the Kreyenborg screen changer and BKG hydraulically adjusted underwater Pelletizer)
For further details please contact KREYENBORG UK Agents Regis Machinery (Sales) Ltd www.regismachinery.co.uk
Aurora Website :- www.auroramanufacturing.co.uk

VIDEO ANIMATION - Press on the Screen Below to view the 3D VIDEO Animation

Melt Filtration at Constant Pressure

Inline compounding of PET bottle flakes on twin-screw extruders is imposing ever greater demands on melt filtration. A newly developed piston-screen changer allows highly effective backflushing of the filter elements with little pressure fluctuation, even in sensitive applications.

KREYENBORG Screen changers are utilised for the continuous filtration of polymer melts for a wide variety of applications including : comnpounding, extrusion recycling, film, sheet, pipe and strapping tape extrusion to name a few of the applications where you can find Kreyenborg screen changers in daily operation. 

Download PDF Press Release about Pressure Constant Screen Changer 

Download CLICK HERE

Kreyenborg Screen Changer from Regis on Vimeo.