New waste water treatment system enables recycling plant to make major improvements
UK Extrusion was proud to work with Clearfox/PPU on this project in the summer which saw customer Coveris upgrading its de-inking and recycling facility, ReCover, with the installation of a new water treatment system. This development is set to improve both environmental and operational performance.
Aligned with Coveris’ No Waste sustainability strategy and its ReCover mission to keep plastic circular, the recycling facility in Louth, Lincolnshire (UK), employs innovative de-inking technology to transform printed polyethylene (PE) residual waste into high-quality recyclate, known as ReGen.
Water plays an essential role in the de-inking process, and the new treatment plant, supported by an onsite ReCover Lab, achieves greater control over water quality for improved recycling and repelletisation. This advancement leads to cleaner, more consistent, and higher quality ReGen pellets, with significant sustainability and operational benefits for the ReCover Louth plant.
The new ClearFoxtreatment plant was developed exclusively for the facility through a collaboration with PPU Environmental Technology GMBH and UK Extrusion Ltd. The water treatment follows a three-stage process: pH correction, coagulation, and flocculation, to remove waste material, and supports optimisation of the de-inking process by enabling onsite treatment, improved automation, and more efficient chemical usage.
Significant reduction in water consumption and transport emissions The environmental benefits of the new treatment plant are notable, reducing overall water consumption while increasing the volume recycled by 35% versus the previous water treatment installation. The volume of water transported offsite for treatment has been reduced by 70% since the opening of the ReCover Louth recycling facility, dramatically cutting transport emissions. As part of stringent water quality controls, technicians in the ReCover Lab conduct onsite testing, which is further validated by external bodies, with the aim of achieving full ‘discharge to drain’ by Q1 2025, pending approval by the local water authority.
Closing the plastic loop The ReCover Louth facility is key to supporting Coveris’ sustainability strategy as it processes packaging waste from the group’s own manufacturing operations, its customers, and the wider industry. The waste feedstock is de-inked, recycled, and repelletised into ReGen, and used as UK Plastic Packaging Tax-compliant recycled content in Coveris’ sustainable packaging solutions. By removing ink during recycling, ReCover enables materials that were once downcycled to remain in the packaging supply chain as part of a circular lifecycle.
Mark Dalby, ReCover UK Managing Director, commented: “When we first launched the ReCover de-inking facility, Coveris set a new standard for recycling innovation in the packaging industry and developed a unique integrated set-up for high-quality recycled content in packaging films in the UK and beyond. This upgraded water treatment plant builds upon that foundation, helping us further optimise our processes while enhancing sustainability.
“By treating more water onsite, we’re not only increasing efficiency but also reducing our environmental footprint while improving the quality and consistency of our ReGen recycled resin. No Waste is at the heart of Coveris’ operations and packaging sustainability strategy; this new addition to the ReCover Louth plant is another step forward enhancing our environmental performance”, added Dalby.
In recognition of Coveris’ commitment to sustainability, ReCover Louth, opened in May 2023, received the top award for ‘Environmentally Sustainable Company – Production’ at the FlexoTech Awards in October 2024. Coveris’ ReCover also won the Green Packaging Star Award 2024 in the ‘Environmentally Friendly Production Process’ category, presented by Kompack and the Austrian Research Institute for Chemistry.
Contact Steve Trainor for further information about how UK Extrusion can help you improve your recycling processes at steve.trainor@ukextrusion.com
December 18, 2024
Case Study: MICROEX CAST + MDO | Benchtop Cast Line with Stretching Technology
We are excited to introduce our latest advancements in laboratory extrusion: MICROEX CAST, now equipped with MDO (Machine Direction Orientation) technology. Optimised Industrial Processes: Small-Scale Testing for Big-Impact Solutions
This updated configuration of our MICROEX CAST benchtop cast film machine is specifically designed to enhance industrial process efficiency by testing new formulations on a small scale. By integrating MDO stretching technology this system unlocks the potential of a wide range of materials, paving the way for cutting-edge solutions in the plastics industry.
Sustainability Meets Cost Efficiency
Polyethylene (PE) is one of the materials that benefits the most from this technology, significantly improving the stiffness, transparency, and barrier properties of the film, making it an effective substitute for materials like PET or PP. Linear low-density polyethylene (LLDPE) also sees remarkable advantages, enabling the production of thinner films that retain or enhance mechanical performance while reducing material consumption and operational costs.
Advantages and Performance
The adoption of MDO offers several key benefits:
Enhanced Mechanical Properties: MDO-treated films exhibit greater tensile strength, reduced elongation, and improved dimensional stability.
Optimised Optical Properties: The orientation process enables higher transparency and better gloss, ideal for aesthetic applications.
Improved Barrier Performance: The technology enhances resistance to gases, moisture, and external agents, making films suitable for food and industrial packaging.
Thickness Reduction: MDO allows the production of thinner films without compromising performance, reducing material usage and costs.
Versatile Applications of MICROEX CAST + MDO Technology
This laboratory machine is highly versatile and supports a wide range of applications, including food packaging with high-barrier films for extended preservation, industrial applications requiring durable films for protective layers and insulation, and the development of mono- and multi-layer materials optimized to meet sustainability standards, such as stand-up pouches and recyclable laminates.
Find out More about our laboratory solutions by talking with our experts. Contact us today!
EUR.EX.MA provides an extensive portfolio of complementary products from all Syncro Group companies—Syncro, Plantech-CST, Plasmac, AceLabs, and SBDry. United by the ambitious #ZEROWASTE project, we aim to reduce post-industrial waste and energy consumption, thus opening and closing the loop of the circular economy.
November 27, 2024
British Plastic Federation Automotive Seminar
Our Sales Director Stefano Nestri is spending his birthday in Edgbaston today, learning about the latest developments in plastics technology for the automotive sector. Happy birthday Stef!
UK Extrusion supply and install Plasmac repelletisers. Plasmac design and manufacture a range of powerful scrap reclamation solutions for plastics processors requiring effective post-industrial scrap and trim reclamation in order to maximise their competitive edge.
SLITTER REWINDERS AND LASER SYSTEMS:CONVERTERS’ PERFECT COMBINATION
TEMAC and SEI LASER: a perfect example of integration between two innovative and complimentary technologies.
A major customer in the converting industry believed in the advantage of installing an innovative and high-performance laser marking and macro-micro perforation system, like the ones designed and created by SEI LASER, on a TEMAC slitter rewinder machine, and the result has been excellent!
The slitter rewinder model is SRS 861, a compact machine characterized by a shaftless unwinding cart and two rewinding stations, everything on the front side. SRS 861 joints the extremely compact design of a single-side working station, with the possibility to handle big diameters. This machine can work a great number of flexible materials for many different needs: this feature has been highly appreciated not only by this specific customer, but also by other users of TEMAC machines.
These slitters are equipped as standard with a control console with an industrial Panel PC IP65 fanless with 15.6” Touch-Screen. The HMI interface design, based on one of the most powerful SCADA on the market, has been called “PCVISION”: it gathers all the machine’s functions and working parameters with simple, intuitive graphics, contextual help on every touch button, diagnostics offering extensive description and 3D images.
For what external connectivity is concerned, PCVISION allows several possibilities: from web sharing to connection of peripheral devices such as printers, code or RFID readers, images mirroring, additional software installation as MES, ERP, PLM ecc.
All the main hardware devices are linked together on EtherNet backbone, so as to be remotely interrogated or programmed.
The PC VISION interface combined with a real industrial PC makes the machine completely transparent and usable in combination with systems of different origins, as for example marking systems, slitting, perforation, die-cutting and decoration by SEI LASER.
Pioneer of laser technology in graphics and industry, over the years this company has verticalized its offer in textiles, label die-cutting, paper converting, flexible packaging, clothing & footwear (leather goods, denim and technical fabrics), and wood, but the field of laser applications can be further expanded.
Thanks to this integration readiness, the installation of a laser marking system on the SRS 861 slitter rewinder was successfully carried out: in just one day of work, directly at the customer’s site, all tests were carried out smoothly, to the great satisfaction of the technicians of both companies, present on site to ensure efficient and scrupulous work.
Obviously, the customer was also satisfied with the investment, which proved to be profitable and far-sighted, and will allow him to maximize productivity and have a high-quality finished product.
The added value of the TEMAC – SEI LASER cooperation undoubtedly lies in some key factors: on the one hand, the technical and technological predisposition that makes the machines perfect for integrating with each other, and on the other, the attention to the customer, both as taking charge of initial requests without fear of distorting the products “in the catalogue” to meet specific “customisation” needs, and as care of the finished work and after-sales assistance.
In addition, the “green” aspect is held in high regard by both companies. As far as TEMAC is concerned, the slitter rewinders meet the requirements of Industry 4.0 and 5.0, since among the more than 700 variables exchanged between the Industrial PC and the customer’s software there may also be those relating to energy consumption. In the machine configuration with 3 or more motors, moreover, the SRS 861 can also contribute to energy saving, since the running motor instead of causing energy dispersion into the environment in the form of heat (as a common axis managed by a brake would do), acts as an energy generator, energy that is then used by the machine itself.
As far as SEI LASER is concerned, the use of laser technology makes it possible to reduce the waste of raw materials and to optimise resources to obtain the best quality while minimising the environmental impact. Applied to sustainable, renewable and recyclable materials, laser technology makes it possible to obtain an all-round sustainable production process.
To discuss your slitter rewinder requirements please contact Stefano Nestri on 07547114153 or email stefano.nestri@ukextrusion.com
November 19, 2024
Improve quality and save costs with Zyroblock from Syncro-Group.
This secondary blown film bubble cooling system is essential for plants where the film temperature causes a risk of blocking the haul-off.
**Reduce the film temperature by up to 15 degrees **Reduce the use of expensive anti-blocking additives **Increase output per hour of up to 20% **Easy install with existing bubble cages or as a standalone **Suitable for diameter 350mm to 3500mm
Case Study: Recycle your scrap with a Plasmac Repelletiser
Increase efficiency, improve quality and reduce recycling costs. Our case study demonstrates how you can do all this and get a return on investment in less than a year.
Get in touch for further information. Contact Stefano.Nestri@ ukextrusion.com
Bandera design and manufacture high performance, advanced technology, multilayer extrusion lines for the production of top quality single layer and multi-layer films for technical packaging: suitable for food, medical, pharmaceutical and mechanical (e.g. automotive) applications.
See the BarrierFlex 9 Layer in action at Bandera’s House of Extrusion in January. Why not plan a visit to Europe’s most innovative research and development centre for packaging and converting? We’d be delighted to show you around. It’s close to Milan Malpensa airport so easily accessible. You will be impressed by what you will see.
Give Steve Trainor a call on 07970272039 or email steve.trainor@ukextrusion.com
October 9, 2024
Exciting new technology from our partners EUR.EX.MA
The MiniFoil C52 is a tailor-made laboratory machine designed to reproduce the PVC and TPO extrusion coating process on a small scale.
This line has various additional components and features: ✅ Horizontal Flat Die allows precise control of film thickness ✅ Three Rolls Vertical Calender with independent thermoregulation for each roll ✅ Counter-Rotating Twin-Screw Extruder to process PVC and TPO ✅ Extrusion Coating System to create laminated films with several materials ✅ SB DRY Volumetric Dosing Unit to allow the perfect material flow ✅ Edge Trimming System to align the edges and save excess material
We have UK based engineers, offering a range of services including project management, turnkey engineering solutions, line upgrades, machine moves and installations, full factory moves and preventative maintenance visits.
This month, we are continuing work on the relocation of an entire Bandera – Extrusion Intelligence line and have installed a new turret winder.
Put your scrap material to good use by recycling it. Add it back into the manufacturing process, save material, save money and help to save the planet’s resources.
The Plasmac Alpha XS is the smallest repelletiser on the market. It has a throughput of 40kgs / hour, takes up a mere 1.5m of factory floorspace and produces high quality pellets ready to re-use.
Our UK based engineers will install, commission, train operators, service and provide ongoing preventative maintenance.
Utilising Plasmac’s patented Short Screw Technology (SST) based around a dual diameter 8:1 L/D ratio screw.
Minimal power consumption and the highest output / kW installed power in the market.
Low shear, minimum process dwell time, minimum material degradation = improved profitability
Extrusion design, no prior size reduction required.
Smallest footprint extrusion machine available on the market.
Perfect for in-line trim recycling.
Available in air-cooled and water-cooled designs
Select from manual or fully automatic screen-changers.
Trim basket optional for feeding inline trims directly into the extruder
Reelfeed optional for feeding reels or scrap reels directly into the extruder
Supatrim – for conveying tacky materials
Flakefeed – to feed in pre size reduced flakes or chips
Machines are available for sale now! Ask us for further information.
