Extrusion Asia Edition 1-2025

29 EXTRUSION & RECYCLING ASIA 1/2025 production facility in Telangana, India, to increase ex - ible packaging production capacity. To further enhance its technological capabilities, Es - ter Industries has chosen to install a Gneuss OMNI 200 recycling system at its new Hyderabad facility, enabling efficient processing of bottle flakes into food-grade pel - lets for use in BOPET film production. Gneuss, known for its advanced recycling technologies, is supplying this state-of-the-art system that processes 2,000 kg/h of bottle flakes collected from India and the surround - ing regions. These bottle flakes are directly converted into food grade pellets without the need for pre-drying or crystallisation. The pellets produced by the OMNI 200 Recycling System will be used in Ester's BOPET film production lines. The OMNI Recycling System consists of a 3C Rotary Feeder, which ensures constant feeding of the extrud - er for maximum process stability, even with fluctuating bulk densities. It also includes an MRS extruder, which is based on conventional single-screw technology but incorporates a multi-screw devolatilisation section. This design enables highly efficient and gentle decontami - nation of the polymer melt, ensuring that the material meets the stringent standards for direct food contact ap - plications. The OMNI Recycling System for Ester Indus - tries uses an MRS 200 extruder that degasses the melt at an absolute pressure of 25 mbar, allowing the use of a robust water ring pump vacuum system. A unique feature of this OMNI 200 recycling system in Ester's new production hall is the dual ltration process, which allows ne ltration down to 16 to 20 µm. This qual - ity is essential for the e cient processing into BOPET lm. It is made possible by two RSFgenius ltration sys - tems that provide maximum ltration quality with minimal material loss. These fully automatic ltration systems operate with integrated back ushing systems, providing self-cleaning without process interruptions or pressure uctuations. This OMNI 200 recycling system is without pre drying which signi cantly reduces the amount of time the material is exposed to heat, allowing for more gentle processing. Another key factor is the advanced ltration technology, which enables ne ltration with exceptionally long screen life, even when processing post-consumer materials. In addition, the system o ers both economic and environ - mental bene ts, including signi cant energy savings and minimal material loss, making it a highly e cient and sus - tainable solution. The new OMNI recycling line is expected to be opera - tional by mid to late 2025. Gneuss Kunststo technik GmbH Mönichhusen 42, 32549 Bad Oeynhausen, Germany www.gneuss.com RECYCLING – CASE STUDY OMNI 200 Recycling System with 3C Rotary Feeder, MRS extruder, water ring pump vacuum system, twin RSFgenius screen changers and pelletising line OMNI 200 回收系统，配备 3C 旋转喂料机、MRS 挤出 机、水环泵真空系统、双 RSFgenius 换网器和造粒线