The goal is clear: the proportion of recyclate in plastic products must be consistently increased. This is the only way to make the circular economy a success. However, the higher the proportion, the more complex the processing. Post-consumer recyclate(PCR) in particular is the supreme discipline here.
The sources of supply available in Germany from the DSD (Duales System Deutschland) - i.e. from the “yellow bag” - present plastics processors with an enormous challenge, as quality and composition fluctuate greatly. The process-stable production of high-quality products often seems impossible. Especially in the area of films and sheets, the technologies established on the market often reach their limits.
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Joint development with special extruders and screw geometries
Together with Reifenhäuser, Pöppelmann has developed a sophisticated solution for this complex task. After extensive test runs at the Reifenhäuser Technology Center at the company's headquarters in Troisdorf, the lines were equipped with specially developed extruders and screw geometries that precisely meet customer requirements and enable thermoformable PP (polypropylene) films for the production of plant pots made of 100 percent PCR. The systems were integrated into a thermoforming production line as an inline process at two Pöppelmann sites in Germany and the USA running in 24/7 operation.
Highest safety standards and calendering norms
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| Thanks to specially developed extruders and screw geometries as well as a digitally optimized inline process, Reifenhäuser Value Sheet Inline systems enable the production of thermoformable PP sheet for the manufacture of plant pots made of 100 percent PCR |
As the company states, Reifenhäuser Value Sheet systems guarantee the highest quality and reliability in compliance with the highest safety standards and the so-called calender norms, which is an important prerequisite, especially at highly regulated production sites.
Pöppelmann operates the systems not only in Germany, but also at its production site in the USA, taking into account all the necessary US norms and standards. The systems and the production process are internationally compatible and were put into operation quickly and reliably with the support of the Reifenhäuser experts.
Jürgen Frilling, Head of Purchasing at Pöppelmann: “In this project, we were able to show that high-quality plastic products can be manufactured from 100 percent recyclate with fluctuating quality in a process-stable and economical manner.”
