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VACUREMA® bottle-to-bottle

Food contact approved

 

Unlike conventional bottle-to-bottle processes, with VACUREMA® technology, decontamination takes place already at the PET flake stage – and not until after they are in pellet form. As a result you are faster in obtaining a top quality, consistent, ultra-clean, food contact approved end product.

Moreover, it gives you a high degree of flexibility as a result, because the technology evens out any differing moisture and IV values in the input material.

Thanks to the pretreatment of the PET flakes at high temperature and vacuum, moisture and migration substances are removed from the material effectively and in a stable process environment already prior to extrusion. This prevents any hydrolytic and oxidative decomposition of the melt in the extruder. A clear bonus for the quality of your end product.

End product: top quality

Clean, food contact compliant, IV stable and best colour results

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  1. Food contact compliant:

    Thanks to highly efficient decontamination the system fulfils and also far exceeds all well-known minimum purity requirements for direct food contact already after the batch process.

  2. With vacuum and top homogenisation for stable IV values:

    The system achieves stable IV values despite varying moisture levels and different IV values in the input material. The pretreatment in the two crystallisation dryers is essential for this IV stability. This takes place under vacuum and makes for excellent homogenisation of the material.

  3. Top colour values. Stable colour values.:

    Melting under vacuum and an overall very short residence time of the PET material inside the system – thanks to this particularly sensitive processing, VACUREMA® gives you recycled pellets with top and stable colour results – with a shape and appearance on a par with virgin material!

  4. Clean melt for clean preforms:

    Thanks to the efficient ultra-fine filtration, the smallest of contaminants such as aluminium and steel particles are removed from the PET melt highly effectively and in a material-friendly way.

Food contact compliant

Thanks to highly efficient decontamination the system fulfils and also far exceeds all well-known minimum purity requirements for direct food contact already after the batch process.

With vacuum and top homogenisation for stable IV values

The system achieves stable IV values despite varying moisture levels and different IV values in the input material. The pretreatment in the two crystallisation dryers is essential for this IV stability. This takes place under vacuum and makes for excellent homogenisation of the material.

Top colour values. Stable colour values.

Melting under vacuum and an overall very short residence time of the PET material inside the system – thanks to this particularly sensitive processing, VACUREMA® gives you recycled pellets with top and stable colour results – with a shape and appearance on a par with virgin material!

Clean melt for clean preforms

Thanks to the efficient ultrafine filtration, the smallest of contaminants such as aluminium and steel particles are removed from the PET melt highly effectively and in a material-friendly way.

Advantages

 
  • Ultra-clean rPET pellets
  • For direct food contact with an IV value on a par with virgin material
  • Flexible input, consistent output: consistent end products in terms of IV value and colour despite varying moisture, IV values, bulk densities and flake wall thicknesses of the input material
  • Maximum resource efficiency: technology saves energy, water and space
  • Easy to operate, high degree of automation
  • Reliable and proven: Overall VACUREMA® capacity worldwide: more than 1.2 million tonnes of rPET per year
 

IMPRESSIONS

VACUREMA® PRIME

 
 

How it works

VACUREMA® PRIME

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  1. PET flake pretreatment:

    Highly efficient decontamination
    The patented pretreatment at elevated temperature and under vacuum before the extrusion process removes moisture and migration materials from the feedstock very effectively and in a stable process environment. This prevents any hydrolytic and oxidative decomposition of the melt in the extruder.

  2. IV increase:

    IV value is increased to the required level.

  3. Melting under vacuum:
  4. Low thermal stress:

    The very short extruder screw without additional extruder degassing reduces the thermal stress on the material through minimised dwell time.

  5. Large area ultrafine melt filtration:

    The robust, fully automatic filter removes even the smallest of aluminium, steel and other particles from the melt. The very large active filter areas enable filtration with up to 32 μm fineness with a low pressure level. The result is highly clean pellets.

 

Two parallel vacuum crystallisation dryers are filled with amorphous, washed PET flakes. The crystallisation dryers work in proper batch mode. The exceptionally high level of purity of the rPET that is produced is achieved by an exactly defined and guaranteed minimum treatment time for every single thin-walled PET flake in vacuum and at increased temperature. The decontamination requirements specified by authorities and brand owners are fulfilled through the adjustable batch times.

The two identical crystallisation dryers are situated immediately upstream of the continuously operating vacuum reactor. The IV increase of the PET flakes takes place inside the reactor through solid-phase polycondensation which takes it to the required level. The material is melted under vacuum in the directly connected extrusion system.

The benefits of the VACUREMA® extruder: robust single screw technology and compact design for minimum thermal material stress.

 
 

decontaminates

homogenises

warms

dries

compacts

buffers

doses

 

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