Gneuss: New Extrusion Line for Polyester Strapping Production at Czech Company Unipack

Gneuss Omni recycling system integrated into strapping production at Unipack – (Image: Gneuss).

Czech packaging manufacturer Unipack has modernized its polyester strapping production line by replacing an existing extruder with a Gneuss Omni extrusion system. According to the company, the new line has been in operation since early 2026 and delivers higher production output, more stable processes, and significantly lower energy consumption.

Unipack manufactures polypropylene and polyester strapping on several production lines and has continuously expanded its capacities in recent years. As part of the modernization project, a Gneuss extrusion system was installed, consisting of a four-component dosing system, an MRS 90 extruder, a vacuum unit operating at 25 mbar, the "RSFgenius" melt filtration system, a "VIS" online viscometer, a melt pump, and a strapping die.

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A key advantage of the new technology is the elimination of the previously required material preparation stage. Processing is carried out without upstream drying and crystallization, which had previously required residence times of five to six hours. At the same time, online monitoring of material viscosity enables continuous process control.

According to Unipack, production stability has improved significantly. The scrap rate has been reduced from seven percent to three percent. In addition, substantially fewer strap breaks occur, reducing production interruptions.

The company has also achieved considerable energy savings. The new Omni system consumes around 40 percent less energy than the previously used production line. This is mainly due to the elimination of energy-intensive pre-drying and the energy-efficient design of the extrusion system.

As a raw material, Unipack primarily processes colored PET bottle flakes, including green, red, and brown materials that are generally no longer suitable for the production of new beverage bottles. The system is capable of processing up to 100 percent recycled material.

In addition to higher throughput, the company highlights improved product quality. In particular, the mechanical properties of the strapping, including elongation and tensile performance, have been enhanced. According to Unipack, the consistent quality of the products has also been positively acknowledged by end customers.

More information: gneuss-mc.com, www.gneuss.com, www.unipack.cz

Gneuss Kunststofftechnik GmbH + Gneuss MC GmbH & Co. KG, Bad Oeynhausen

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