Extrusion International 6-2024-USA

49 Extrusion International 6/2024 RECYCLING – CASE STUDY Sustainable Packaging with Recycling Technology Ester Industries is planning to install Gneuss OMNI 200 system to boost sustainable BOPET film production, aligning with India's 2025 recycling goals and regulatory requirements. I ndia has set a goal to reduce plastic waste and promote a circular economy. Comprehensive waste collection systems and recycling infrastruc- ture will be in place by 2025 to increase the amount of recycled material in packaging. The Indian gov- ernment is strengthening its Extended Producer Re- sponsibility (ERP) regulations, with a particular focus on mandatory recycling quotas. Companies must ensure that a certain percentage of their packag- ing is made from recycled material. The quotas vary depending on the type of material and packaging and include both post-industrial and post-consumer waste. The recycling quotas are intended to increase the demand for recycled raw materials and strengthen the market for recyclates. Ester Industries is a leading global manufacturer of polyester (PET) film, specialising in value-added and speciality products. Established in 1985, the company operates state-of-the-art manufacturing facilities in Khatima, Uttarakhand, and Hyderabad Telangana In- dia, and is known for producing high quality BOPET film. Ester serves a global market with exports to over 85 countries and offers an extensive product portfolio. Ester Industries is committed to sustainability, as dem- onstrated by its development of post-consumer recycled (PCR) PET film. The company continues to expand its op - erations with significant investments such as a new pro - duction facility in Telangana, India, to increase flexible 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 surrounding 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 pro - duction lines. The OMNI Recycling System consists of a 3C Rotary Feeder, which ensures constant feeding of the extruder 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 applications. The OMNI Recycling System for Ester In- dustries 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 filtration pro - cess, which allows fine filtration down to 16 to 20 µm. This quality is essential for the efficient processing into BOPET film. It is made possible by two RSFgenius filtra - tion systems that provide maximum filtration quality with minimal material loss. These fully automatic filtra - tion systems operate with integrated backflushing sys - tems, providing self-cleaning without process interrup- tions or pressure fluctuations. This OMNI 200 recycling system is without pre dry- ing which significantly reduces the amount of time the material is exposed to heat, allowing for more gentle processing. Another key factor is the advanced filtra - tion technology, which enables fine filtration with ex - ceptionally long screen life, even when processing post- consumer materials. In addition, the system offers both economic and environmental benefits, including signifi - cant energy savings and minimal material loss, making it a highly efficient and sustainable solution. The new OMNI recycling line is expected to be opera- tional by mid to late 2025. Gneuss Kunststofftechnik GmbH Mönichhusen 42, 32549 Bad Oeynhausen, Germany www.gneuss.com OMNI 200 Recycling System with 3C Rotary Feeder, MRS extruder, water ring pump vacuum system, twin RSFgenius screen changers and pelletising line