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| 2025-01-06, 14:05 |
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Gneuss: Project for the production of stretch film with recycled content - Cooperation with Colines and ExxonMobil Signature Polymers
 Production line with Gneuss RSFgenius filtration system in Europe - (Pictures: Gneuss). In response to this, new capacity has been built or existing plants have been retrofitted with improved sorting, washing or additional melt filtration systems in order to offer high-quality polyethylene (rPE) for recycling. However, even LDPE/LLDPE that has undergone extensive mechanical processing is often difficult to reprocess into new film on conventional production lines. Colines, ExxonMobil Signature Polymers and Gneuss have now joined forces in a development project to develop a viable film manufacturing process with cost-saving potential. In particular, the so-called “gels” and “black spots” are considered to be disruptive factors that could be minimized with the appropriate materials from ExxonMobil Signature Polymers and a pressure-constant screen changer from Gneuß on a highly flexible cast film line from Colines. Advert According to a press release, the experts at ExxonMobil Signature Polymers have conducted trials with PCR material (Post Consumer Recycled) made from stretch film in combination with the high-performance polyethylene “Exceed Tough m 3812” and have observed a reduction in the size of the larger polymer gels.
"It is further stated that for most of the commercially available PCR types on the European market today, the extrusion lines often cannot run continuously. Continuous filtration could help to ensure that extrusion lines can be operated over longer periods of time. Filtration removes a significant portion of the impurities from the melt, but not all gels,” says Bart Lauwers, Principal Extrusion Customer & Application Development at ExxonMobil Technology Group. However, the project has proven the quality and consistency of the process. All the tests carried out have shown that it is possible to produce film with a PCR content of 30 percent for automatic use with a consistency of 180-200 percent without having to stop the line except for routine work unrelated to the use of recyclate (e.g. cleaning the lip stamps, cleaning the chill rolls, changing the recipe or the film format). A key component in this process is the patented Gneuss RSFgenius self-cleaning screen changer. This fully automatic filter system would replace the screen area without measurable pressure fluctuations and can be adapted to the respective material, with screen fineness typically between 30 and 75 µm, even during full operation.  RSFgenius filtration system in operation at Colines’ technical center The collaboration between Colines, Gneuss and ExxonMobil Signature Polymers has already resulted in several large-scale production lines specifically for the incorporation of recyclates, with many more in the pipeline globally for various markets. In the first months of 2025, the project partners plan to invite interested professionals to Novara, Italy, again to simulate their own requirements for such a production line in individual demonstrations. A Colines plant with a fully integrated RSFgenius 150 should be available to achieve film thicknesses of up to 10 µm consistently and without quality fluctuations. ExxonMobil's Signature Polymers expertise in the selection of materials and additives should also be available for these trials. More information: |
Gneuss Kunststofftechnik GmbH, Bad Oeynhausen, Germany
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