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COREMA®

Recycling and compounding in a single step

 

A powerful, energy and time-saving innovation from EREMA: COREMA® combines the benefits of recycling and compounding in a single plant. This system produces tailor-made tunable recycling compounds for especially high quality applications.

Recycling raw materials such as PP fleece, PE edge trim, PA fibres are transformed into a filtered melt using proven, robust EREMA technology which is then fed directly to the Coperion co-rotating twin screw extruder.

With its excellent mixing and gas removal properties, this part of the system can handle all compounding tasks. Besides the dosing of a wide variety of additives, high amounts of fillers and reinforcing agents can be admixed.

Technical benefits

 
  • Flexible input of various recycling raw materials thanks to the preconditioning unit and Counter Current technology
  • Proven, robust EREMA technology for producing filtered melt material
  • Minimum thermal stress through short, defined dwell times and direct dosing of the melt in the twin-screw/compounder/extruder
  • Proven EREMA degassing technology with EREMA preconditioning unit and extruder degassing
  • Central user interface to control the whole system

Economic benefits

 
  • Increased value added thanks to the use of inexpensive raw materials (e.g. PP non-woven, PE edge trim, PA fibres etc.) 
  • Very low operating costs and minimal specific energy costs through direct dosing of the filtered melt and processing in a single heat 
  • Modular system concept offers optimum adjustment to the respective application 
  • Reliable production thanks to Counter Current technology and very robust design 
  • Compact, space-saving design 
  • ecoSAVE® reduces energy consumption by up to 12 % as well as production costs and CO2 emissions as a result
 

IMPRESSIONS

COREMA®

 
 
 

How it works

COREMA®

 
1 2 3 4 5 6 7 8 9
  1. FEEDING:

    Feeding (1) is automatic according to customer requirements.

  2. PRECONDITIONING UNIT:

    In the patented Preconditioning Unit (2) the material is cut, mixed, heated, dried, pre-compacted and buffered.

  3. Extruder screw :

    In the extruder screw (3) the material is plasticised and homogenised.

  4. Filters:

    The melt is then cleaned in the fully automatic, self-cleaning filter (4)

  5. Melt pump :

    The prepared and cleaned melt then goes via the melt pump (5) directly to the co-rotating, self-cleaning twin-screw extruder (6) from Coperion.

  6. Twin-screw extruder:

    Co-rotating, self-cleaning twin-screw extruder (6) from Coperion

  7. Fillers and reinforcing agents:

    Besides the dosing of a wide variety of additives, high amounts of fillers and reinforcing agents can be admixed (7)

  8. Degassing zone:

    The compounded melt is degassed in the degassing zone (8).

  9. Tools:

    The degassed melt is fed into the relevant system (9) (e.g. EREMA hot die face pelletising system)

Feeding (1) is automatic according to customer requirements. In the patented Preconditioning Unit (2) the material is cut, mixed, heated, dried, pre-compacted and buffered. Next, the tangentially connected extruder is filled continuously with hot, pre-compacted material. 

In the extruder screw (3) the material is plasticised, homogenised and then cleaned in the fully automatic self-cleaning filter (4). 

The prepared and cleaned melt then goes via the melt pump (5) directly to the co-rotating, self-cleaning twin-screw extruder (6) from Coperion. With its excellent mixing and gas removal properties, this flexible part of the system can handle all compounding tasks.

Besides the dosing of a wide variety of additives, high amounts of fillers and reinforcing agents can be admixed (7). In the degassing zone (8) the compounded melt is degassed and then fed into the respective system (9) (e.g. EREMA hot die face pelletising system).

 

cuts

homogenises

warms

dries

compacts

buffers

doses

 

GROUNDBREAKING INNOVATION

Counter Current technology developed by EREMA changes the direction of rotation inside the preconditioning unit: the plastic material thus moves in the opposite direction to that of the extruder screw. A small change with a big impact: the relative speed of the material in the intake zone, i.e. when passing from the cutter/compactor to the extruder, accelerates so that the extruder acts in the same way as a sharp cutting edge which literally "slices up" the plastic.

 

As a result the extruder handles more material in a shorter time. Thanks to the enhanced material intake plastic can be processed even at lower temperatures at a high throughput - meaning higher productivity, flexibility and operational reliability.

ENERGY EFFICIENT AND ENVIRONMENTALLY FRIENDLY:

 
eco_save.png
 
 

ecoSAVE®  technology

  • Lower specific energy requirements thanks to a complete package featuring design and process engineering measures, such as the new direct-drive extruder screw
  • Lower production costs through optimised control technology and high-quality, energy-efficient components such as high-performance motors
  • Additionally, the practical energy display on your operating panel gives you a constant overview of energy consumption at all times, thus enabling you to take specific measures to optimise consumption
  • Reduced CO2 emissions – an important contribution to environmental protection

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