ADVANCED EXTRUSION SOLUTIONS FOR BIOPLASTIC RECYCLING

Euroviti recently partnered with an innovative customer specializing in the production of bioplastic films. The customer’s goal was to improve their sustainability efforts by recycling scraps and offcuts, thereby optimizing resource use, reducing waste and lowering costs. In this new success story, we will tell you how Euroviti’s customized extrusion solutions enabled the customer to achieve remarkable production efficiency and sustainability.

Environmental problems caused by the dispersion in the environment, or the incorrect use of plastic have paved the way for the search for eco-sustainable substitutes. Like traditional plastic, bioplastics are often considered its potential successor. Bioplastics, derived from renewable sources such as corn starch, potatoes, algae and sugar cane, are increasingly used in various sectors, including packaging, automotive, medicine, agriculture and 3D printing. The range of available materials is vast, each with different characteristics and process requirements, both for injection and extrusion; however, it is essential to proceed with correct drying and processing without generating stress on the melt.

One of the projects that made us happiest, not only thinking about the results obtained in terms of production but also for being able to reuse old components, can be summed up in one key word: RE-USE.

Our client, a Mater-Bi film manufacturer, faced the challenge of recycling production waste and our proposal was to do so by designing and recovering and re-using as much as possible from an obsolete extruder.

Euroviti’s technical team designed a new extrusion solution tailored to the customer’s needs. The old extruder, over 40 years old, abandoned in a warehouse, had a diameter of 90mm L/D12 and a 30Kw motor. It was transformed into a high efficiency system by incorporating a new 70mm L/D37 plasticizing unit with degassing system and a dedicated screw profile. This innovative approach allowed the customer to reuse existing components, including motor, gearbox and die-head, significantly improving production capabilities.

The updated system achieved impressive results:

• Production efficiency: The new extruder allowed a production of 200 kg/h of recovered granules at 120 RPM.
• Sustainability: By recycling scraps and offcuts, the customer has optimized the use of resources, minimized waste and reduced overall production costs.
• Quality improvement: The customized screw profile ensured high-quality workmanship, meeting the customer’s needs both qualitatively and quantitatively.

This challenge with bioplastics has also been successfully overcome. Thanks to our customized solutions, we have helped the customer optimize production processes and achieve important sustainability goals. If you also want to improve the efficiency of your production and reduce environmental impact, contact us