With its unique MRS Recycling Technology for PET bottle flakes, Gneuss Kunststofftechnik GmbH, Bad Oeynhausen, Germany, produces production of sheet, film, tapes, fibers and new bottle pellets on the whole world market

The decisive argument for many processors in favor of a Gneuss solution is the unrestricted FDA approval for the materials produced with this process. This is the reason why also the two Brazilian companies Unnafibras Textil S.A. (Santo André, SP) and Nova Pack Embalagens Ltda (Bento Goncalves, RS) decided recently to buy Gneuss machinery.

In Brazil, Unnafibras is considered as the leading company in the sector of PET fiber recycling. The company ordered a total of three recycling lines from Gneuss. Two lines were purchased for the production of textile fibers; one was laid out for bottle-to-bottle recycling. At Unnafibras’ headquarters in Santo André, the first two lines produce co-extruded polyester fibres from recycled material, with a total capacity of 1500 kg/h. The third line, which reaches a capacity of 2000 kg/h, is operated in Paraiba. Here, pellets are produced from PET bottle flakes, which are as good as new and which are used by local injection moulding companies for the production of bottle preforms.

Nova Pack is specialized in the production of thermoforming sheet material made of PET, PP and PS. For PET sheet production, they have used in-house or bought-in recycled material for several years now. Now, Nova Pack – who has operated Gneuss Rotary Filtration Systems for about five years—has made the decision to buy an extrusion line with the MRS Extruder. “We are for the first time in a position to produce packagings from 100% recycled material!” This is how Nova Pack’s managing director Ivanor Luis Arioli explained his decision. “We have mainly been convinced by the low costs and the high transparency of the produced film, none of these factors could be realized with traditional systems.”

Gneuss MRS extrusion systems consist of the unique Multi Rotation System Extruder for dehumidification of the recycled material without cost-intensive pre-treatment, a Rotary Filtration System for safe removal of contaminated particles and an online viscometer for fully-automatic control of melt viscosity. The excellent results, which are well suitable for the food sector and which also convinced the FDA Authority, are realized by the MRS Extruder thanks to its optimum decontamination properties. These result in turn from the combination of a very large melt surface in the multi-screw section of the extruder, an intensive melt exchange and an optimum devolatilization. This special recycling system has proved in many applications that it can produce high-quality end products at low energy costs, with minimum maintenance and operating effort and with high production flexibility.
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