Innovations in Extrusion: Unique

Multiple Screw Extruder MRS

Monika Gneuss
Gneuss, Inc.

Polymer Extrusion and Compounding Seminar

May 25-26, 2017
At ICIPC, Medellin, Colombia

Gneuss, Inc.
Who we are Headquarters
Gneuss Germany
Subsidiary
Gneuss at a glance Gneuss, Inc., USA Gneuss Office
Shanghai, China

Gneuss Office
Latin America, Brasil

Extrusion Filtration Measurement

Technology Technology Technology

Gneuss, Inc.
Who we are Bad Oeynhausen, Germany
Gneuss at a glance

about 200
employees
worldwide

More than 100

patents

34 years of 50 % of our
Worldwide distribution
successful
development
turnover in recycling with 55 sales &
applications service locations

Gneuss, Inc.
Devolatilization with MRS Technology
Extrusion line
Filtration Vacuum Technology
System

Online
Viscometer

MRS Technology

Controls

Gneuss, Inc.
MRS Extruder
Design
Transition of Single Screw to Multi Rotation Section

Multi Rotation Section

Transition of Multi Rotation Section to Discharge Screw

Gneuss, Inc.
MRS Extruder
IV

Multi Rotation Section

0,9

0,8

0,7
viscosity i.V. [dl/g]

0,6

0,5

0,4

0,3

0,2

0,1

0
MRS
25 mbar TM = 285 °C

12 D 25 D 12 D

Gneuss, Inc.
MRS Extruder
Animation

Gneuss, Inc.
MRS Extruder

Gneuss, Inc.
 Extrusion Systems
Performance Comparison

Surface Exchange rate

Gneuss, Inc.
Decontamination
With MRS Extruder

FDA LNO for Bottle to Bottle

Washed and unwashed Flakes
Hot- and Cold Fill-Applications
Up to 100 % Bottle Flakes

Gneuss, Inc.
Devolatilization with MRS Technology
Extrusion line
Filtration Vacuum Technology
System

Online
Viscometer

MRS Technology

Controls

Gneuss, Inc.
Vacuum Technology
Water Ring Pump

Suction inlet Pressure outlet

Liquid ring

Filter belt

Gneuss, Inc.
Devolatilization with MRS Technology
Extrusion line
Filtration Vacuum Technology
System

Online
Viscometer

MRS Technology

Controls

Gneuss, Inc.
Online Viscometer
Viscosity versus Vacuum
Melt Viscosity Control
With Online Viscometer

Gneuss, Inc.
Online Viscometer
Viscosity versus Vacuum

800 80

700 70

absoluter Druck p [mbar]

600 60
Viskosität h [Pas]

500 50

400 40

300 30

200 Viskosität Sollwert 20

Viskosität Istwert
100 Vakuum 10

0 0
13:00 13:30 14:00 14:30 15:00
Zeit t [hh:mm]

Gneuss, Inc.
Devolatilization with MRS Technology
Extrusion line
Filtration Vacuum Technology
System

Online
Viscometer

MRS Technology

Controls

Gneuss, Inc.
RSFgenius
Design
Drive Safety Cover

Filter disk

Hatch door for Junction box

Screen changing

Back-flush piston

Screen cavity
Filter block

Melt discharge opening

Melt channel

Gneuss, Inc.
RSFgenius
Active Screen Area Illustration

Gneuss, Inc.
RSFgenius
Animation

Gneuss, Inc.
Application Examples

• Recycling
• Sheet
• Fiber

Gneuss, Inc.
Over 60 MRS extrusion systems sold worldwide

• PET thermoforming sheet (fruit, bakery, packaging, displays)

• PET stable fiber
• PET continuous fiber (BCF)
• PET/PPT fiber recycling
• PET nonwoven
• PET slit-film
• PET strapping tape
• PET bottle to bottle recycling
• BOPET recycling
• polyolefin recycling
• PA recycling

Gneuss, Inc.
 Application Example
PP Recycling
VOC Emission

120
Conventional Twin Screw Extruder
Gneuss MRS System
100
- 11%

80
[%]

60
- 50%
- 56%
40
-77%
20
- 91%

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VOC Emission
os
tm

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Purification of Recycled PP Compound
Thermal Desorption Analysis according to VDA 278
Gneuss, Inc.
 Application Example
PET Fiber Recycling
MRS 90
RSFgenius 90
up to 800 lbs/h

Processing of production waste with subsequent IV-controlled feeding into polycondensation reactor
for direct fiber spinning
Agglomerated PET fibers/lumps
Recycling of BOPET reclaim (film, start-up waste)
Vacuum venting to remove spin-finish oils and water
Feedback from viscosity measurement to glycol feeding and vacuum

Gneuss, Inc.
 Application Example
PET Bottle to Bottle Recycling

2 x MRS 130
2 x RSFgenius 250
2000 kg/h

Production of bottle pellets incl. FDA NOL

Processing of 100% PET bottle flakes
(post-consumer curb side material)
Flexible production of amorphous,
crystalline and crystallized high-IV
material
Recycling of BOPET reclaim (film, start-up waste)

Gneuss, Inc.
 Application Example
PET Bottle Flakes to Staple Fiber

MRS 130
RSFgenius 175
up to 1000 kg/h

Production of staple fiber with a fineness of 6.7 dtex

PET-BF and colorants like TiO2 or carbon black

Gneuss, Inc.
 Application Example
Thermoforming Sheet

Processing of un-dried and un-crystallized

- pellets
- pellet/flake blends
- 100% flakes
Successful processing of APET, RPET, PETG, CPET, DPET
with moisture levels from 30 to 15,000 ppm

Sheet thickness from 8 to 80 mil

Excellent sheet clarity

Gneuss, Inc.
 Application Example
Thermoforming Sheet
Thermoforming sheet for displays
Width: 32 – 36 inches
Thickness: 20-80 mil
Up to 100% PET PCR
Throughput: 800 lbs/h

MRS 90
RSFgenius 75

Gneuss, Inc.
 Application Example
PET Thermoforming Sheet

MRS 130
RSFgenius 150

Production of lids
(inline thermoforming)
Width: 53 inches
Thickness: 10 – 14 mil
Up to 60 % skeleton reclaim
Up to 2,200 lbs/h

Gneuss, Inc.
 Application Example
PET Thermoforming Sheet

MRS 160
RSFgenius 175

Width: 56 inches
Thickness: 12 – 40 mil
Up to 100% reclaim (bottle flakes and regrind)
Throughput : 3,500 lbs/h

Gneuss, Inc.
 Application Example
PET Thermoforming Sheet

MRS 200
RSFgenius 200

Width: 56 inches
Thickness: 12 – 40 mil
Up to 100% reclaim
(bottle flakes and regrind)
Throughput : 4,200 lbs/h

Gneuss, Inc.
 Application Examples
Summary
• Pellets, pellet flake blends, 100 % flakes
• No pre-drying or crystallization
• Simple material handling (no gravimetric feeding required)
• Extremely efficient devolatilization
• High gloss and transparency
• Low yellowness
• FDA LNO for food contact for up to 100 % post-consumer reclaim content
• Direct food contact for both monolayer and co extruded sheet
• Sheet thickness from 150 - 2000 μm
• High IV consistency and online viscosity control
• Easy processing of low melt temperature polymers such as PETG und PE
as well as PET/PETG co extruded sheet and recycling of PET/PE laminated sheet
• Extremely homogeneous, distributive mixing, excellent melt homogeneity
• Major energy savings
• Small footprint

Gneuss, Inc.
Thanks for your attention

Gneuss Technical Center

Gneuss, Inc.