Extrusion International USA 5-2022

66 Extrusion International 5/2022 K 2022 Technical Solution to One of the Biggest Challenges in the Processing of Recyclate T he line manufacturer Reifenhäuser Blown Film has developed a tech- nology that makes blown film produc - ers independent of highly fluctuating recyclate qualities and ensures a stable production process – even when pro- cessing low-quality input material: EVO Fusion upgrades recyclate qualities. With EVO Fusion, blown film produc - ers also process previously unusable, lowest-quality recyclates into high-per- formance blown films for simple appli - cations, such as trash bags or mailing bags. Until now, such low-grade recy- clates could only be used for simple and thick-walled injection-molded prod- ucts. In addition, producers can make higher-quality film from recyclates that could also be processed in the past. Eugen Friedel, Director Sales at Rei- fenhäuser Blown Film, explains, "In order to drive the circular economy, re- cycling content in blown film products must increase and classic downcycling must be limited. With EVO Fusion, we offer a unique process that enables customers to process even low recy- clate grades easily and economically into high-performance products and increase the recyclate content. In this way, processors open up new fields of application for recycled products." The EVO Fusion process relies on direct extrusion, which eliminates the need for energy- and cost-intensive regranulation of the raw material. This means that fluff (film shreds) and all types of production waste and PCR material can also be processed directly. This is made possible by the twin- screw technology, which homogenizes the melt better and thus ensures a stable process. In addition, processors can degas the system very easily and effectively, removing unwanted com- ponents in the recyclate. For processing better quality re- granulates, Reifenhäuser recommends the EVO Ultra single-screw extruder. Thanks to optimized barrier as well as shear and mixing parts, this extruder processes recycled material as reliably and naturally as other raw materials – the ideal prerequisite for success in the growing market for products with a high recycled content. Highly Wear-Resistant Screws and Barrels Enable Safe Recyclate Processing Whether film manufacturer, injec - tion molder or line manufacturer: the processing of recyclate involves many challenges because recyclate is a rather complex raw material and a stress test for the plasticizing unit. Highly wear- resistant barrels and screws from Rei- fenhäuser Reiloy give the unit a long service life and ensure high product quality. Recyclate is often a grab bag, be- cause it is not always clear how careful- ly the startingmaterial has been sorted and cleaned, or which additives and possibly aggressive residual compo- nents are contained. In addition, high- quality recyclate processing requires special additives that enable the poly- mer to become a high-quality product again. However, many of these ad- ditives are also challenging because, among other things, they have an abrasive effect or adhesive tendency - Thanks to the twin screw and degassing unit, the EVO Ultra Twin Extruder can also safely process low-quality recyclate. The system can be degassed very easily and effectively to remove unwanted components in the recyclate Screws and barrels from Reifenhäuser Reiloy regularly set benchmarks in wear protection and offer proven longer lifetime Recyclate is complex as a raw material and a stress test for the components of the plasticizing unit. Abrasion, corrosion and adhesion can lead to surface damage