New demonstration plant launch: From PET bottles straight to packaging

AMUT and EREMA invite guests to experience the closed material loop of PET first-hand from 28 to 31 May 2018. Washed post-consumer PET bottle flakes will be recycled live at the AMUT headquarters in Novara, Italy, to make food contact grade thermoforming sheet in a direct process. This rPET sheet will be used at the Plast Milan exhibition – which is being held at the same time – to make thermoformed trays for the food sector. Interested producers will be able to process their own input material on the demonstration system in future to make plastic rolls. They can then test the samples later in their own thermoforming production to check the quality.

AMUT President Piergianni Milani

AMUT and EREMA are holding an Open House to present a sophisticated "Bottle to Packaging" process and show that the desired closed material loop in the PET sector is already reality. The post-consumer flakes are processed in the new demonstration facility – a direct combination of VACUREMA® technology and the AMUT Inline Sheet plant – in a single process to make food contact grade thermoforming sheet. "Energy savings, IV preservation, lower logistics and process costs lead to higher profitability and are unbeatable arguments which are driving the trend towards direct food grade PET processing," says AMUT President Piergianni Milani.

Thanks to the direct combination of recycling and production technology there is no longer any excess process stage. This is because the melt goes straight from the VACUREMA® to the AMUT plant without the detour of pelletising. "The Open House visitors will hold food contact grade thermoforming sheet produced from 100 per cent post-consumer PET bottle flakes in their hands – without even the slightest amount of virgin material added," says Michael Buchberger, Sales Manager for the Bottle sector at EREMA.

Michael Buchberger, Sales Manager, and Christoph Wöss, Business Development Manager for the application Bottle, in front of the VACUREMA® in the production hall at EREMA

A free shuttle service between the trade fair in Milan and the AMUT headquarters in Novara will be available for attendees. The 100 per cent rPET sheet will be used to make thermoformed trays for the food sector at the AMUT booth during the Plast Milan show. The demonstration facility in Novara will continue to be available for customer trials also after the Plast Milan show. "Our VACUREMA® technology is currently in use on 61 Inline Sheet facilities around the world. You have to be able to rely on the upstream and downstream process, especially in the case of direct processing. With AMUT we are delighted to have found another long-term partner in the Inline Sheet sector," says Buchberger.

100 per cent PET flakes with 100 per cent food contact approval

The post-consumer PET material is already decontaminated and pre-dried prior to extrusion in the vacuum reactor of the VACUREMA® Basic, with a throughput of up to 1,000 kg per hour. The newly developed EREMA PET Laserfilter processes input material with a degree of contamination of over 1 per cent without any difficulty and discharges the filtered particles continuously. Thanks to its unique pressure consistency this filter system is particularly suitable for inline production. Despite varying moisture, IV values and bulk densities in the input material, the melt has a constantly stable IV value and colour. Additionally, the process stands out through what is only a marginal IV drop. The melt then goes directly into the AMUT Inline Sheet plant where it is processed into thermoforming sheet.

The integrated online viscometer shows the user the actual viscosity of the melt. High-stiffness cooling rolls guarantee precise material planarity. Another boost in sheet quality comes from the fully integrated inline thickness gauge control. The hot lamination system represents an additional production benefit and is particularly suitable for sensitive barrier film thanks to the adjustable contact point. The wet coating at the end makes for an antistatic and anti-blocking solution.

The monolayer thermoforming sheet produced from pure rPET is not only 100 per cent food contact compliant, it also fulfils the FDA regulations and EFSA guidelines.

About AMUT Group

AMUT has specialised in building plants for the manufacturing of plastics at production sites in Italy since 1958. AMUT has developed its business and technologies from its beginnings as a manufacturer of extruders. Today the Italian plant engineers can supply complete lines in six different sectors: extrusion, thermoforming, packaging film, recycling, flexo printing and converting.

About EREMA Group

Besides EREMA itself, the EREMA Group comprises 3S, PURE LOOP and UMAC. With EREMA subsidiaries in the USA, China and Russia plus around 50 representatives in all five continents, the EREMA Group has a reliable network to realise customised recycling solutions for international customers. Around 500 people around the world now work for the Austrian company group which is headquartered in Ansfelden near Linz.