viscoSHEET PET extrusion Line ensures outstanding flexibility in production with lowest energy consumption. Up to 100% rPET, in-house waste, and virgin can be processed at guaranteed iV levels.
Max output of extruder 2100-2200kg B and 350-400kg of Extruder A
Material handling :
4x Big Bag unloading station
Volume of hopper: approx. 1000 l
The material is transported from the Big Bag unloading station via a vacuum feeding system to the crystallizer (CRY).
Metal detection/separation
Inlet diameter:76 mm (3 inch pipe)
Material handling and transport to the deCON 75 iV+ (vac. feeding 18m)
2x Material handling and transport from Big Bag unloading station to viscoSHEET
viscotec pre-treatment Crystallizer (cry 20)
The viscotec crystallizer cry 20 performs a two-stage process on PET material. (1) Amorphous material is crystallized by passing the glass transition state and (2) the surface moisture (main moisture content) is removed. The material is pre-heated to the dedicated process temperature.
Consisting of :
Volume of crystallizer tank: 2000 l
Installed power:125 kVA
Heating power:90 kW
Output:Approx. 1000 kg/h on PIR (post industrial regrind)
Material handling and transport from CRY to viscoSHEET
The material is transported via vacuum feeding system (viscoSHEET central vacuum station) to the gravimetric dosing system of the viscoSHEET line.
Max. possible feeding distance 30 m (100 ft).
Consisting of: Feeding accessories kit:1x conveying valve
Assembling material for vac. Feeding: Rigid piping Ø 76 mm (Ø 3 inch)
For material transportation (stainless steel pipe: 6x6 m (6x20 ft) + 12x90° elbow pipe)
Decontamination dryer deCON 75 iV+:
The established TRAY recycling solution. Decontamination dryer for production of dry, iV increased, food grade flakes from bottles and trays, or skeleton waste directly in front of production extruder.
Max. output : 1600-1800kg/h (line efficiency 92.5%), 800-1000kg/h (line efficiency 92.5%) for iV increase of approx . 0,02 to 0,04 dl/g/h
Max. output with flakes iV+ mode2 [kg/h]* 800-1000
Energy consumption [kWh/kg]* 0.10-0.15
Max. surface moisture of input material [%] 1
Output humidity [ppm] <50
Food grade according to EFSA, FDA
Installed heating power:3 x 85 kW (preheaters)
Installed power KAESER air blower:3 x 30 kW
Material handling and transport from deCON to FG buffer and NFG bagging station
Extrusion Part - dosing unit Suction and gravimetric dosing unit for extrusion part
The raw material is transported to the gravimetric dosing unit above the extruder, where each component is individually weighed before being fed into the extruder intake zone. The material feeding is done with the central vacuum station incl. dust filter.
With an additional device the color / liquid additive can be fed into the intake zone of the extruder by a gear pump. A mixing unit is mounted on the top of the unit to assure a homogeneous mixture of the colors. Included are a control unit, light signal, and software integration into the operator panel.
Main-extruder dosing unit
Number of main components:4 (100 l each)
Number of additives:1 (10 l each)
Liquid dosing unit 0.018 – 45 l/h; 0.19 kW, the output of the liquid dosing unit is synchronized to the extrusion output
Edge trim recirculation: Incl.
Main extruder (single screw 215)
The Starlinger single screw extruder is a state-of-the-art technology which captivates by its robustness, the special screw design for rPET flake materials, and the flexibility to process different products for highest quality standards.
Consisting of: Extruder screw:215 mm (8.5 inch)
Extruder length:24 L/D
Main drive power:400 kW AC
Nordson- Screen changer K-SWE-250 4K RS
Automatic back flush
Eprotec- Melt pump
Co-extruder (single screw 85)
Extrusion die 2100 mm
Manual adjustment
Complete with co-extrusion connector; die insulation consists of a ceramic fiber and stainless steel cover, electrical equipment, and internal control thermocouples. Die lip heaters for PET film and PET multi layer structures, lip heaters installed on both sides of die lip area, including electrical equipment. Set fixed external deckles for the flat die 300 mm on each side.
Equipped with gear racks for easy splitting of the die without dismounting.
auto DIE
According to the set point of the thickness control system, the automatic regulation sets up the thickness profile within the tolerance set point. The operator can change the thickness very easily on the control panel and the system is adjusting it automatically.
Roll stack 2000 mm cooled width (total 2100 mm) – high capacity
Roll diameter:500mm/700mm/500mm
Rmax= 0,1-0,2 µm
Roll steel quality:Tool steel, nitride hardened, chromium plated and glossy finish Drives:4 x 7,8 kW servo controlled
Water pumps from cooling device:3 x 7,5 kW ,1 x 15 kW Additional chill roll C3 500mm
Thickness measuring device 2000 mm
Dual sensor: capacitive/eddy-current
Max. possible sheet width: 2000mm
Take-off unit 2000 mm
Edge trim cutting unit 2000 mm
Edge trim granulator
Roller coating system 2000 mm
2nd Take-off unit 2000 mm
multiWINDER two stations– semi-automatic incl. accumulator
Technical data:
Accumulator capacity:60m
Accumulator guide rollers:Ø 160mm Number of webs:1 web per shaft
Max. winding width station 1&2:2000 mm Max. winding width station 3&4:1200 mm Max. winding diameter:1500 mm Max. Roll weight station 1&2:3200 kg Max. Roll weight station 3&4:3000 kg Max. Line speed:60 m/min Thickness range:200-1650 µm*
(*1500µm only with 6” winding shafts)
Consisting of: 5 pcs. winding trolleys with 2 heavy duty rollers and 2 fixed feet 5 pcs. 6” pneumatic winding shafts
Inline viscosimeter iVON
For the inline iV measurement of the actual iV during the extrusion process with two melt pumps and a differential pressure measurement
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