After a phase of comparatively low prices, the market for virgin plastics has shifted significantly. Driven by geopolitical developments, price levels are rising continuously, directly impacting material costs for processors.
As a result, previously stable cost structures are coming under pressure. At the same time, recyclates are gaining renewed relevance – both as an economic alternative and in response to regulatory requirements. Under the EU Packaging Directive, mandatory minimum recycled content targets must be met by 2030.
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OMNI recycling system for processing up to 100% post-consumer material – combining preparation, degassing and filtration |
However, a large share of installed production lines is not designed for higher recyclate input – particularly from post-consumer streams. In addition, increasing recyclate usage typically comes with higher variability in material quality.
Retrofitting existing lines to handle increased recyclate volumes is, in many cases, less complex than assumed. Gneuss provides retrofit solutions that enable existing extrusion lines to process both virgin material and recyclates in a stable and controlled manner – without requiring complete system replacement.
Gneuss Retrofit Concepts
Gneuss retrofit concepts focus on the targeted optimization of extrusion and melt filtration. Combining these process steps enables a Super-Clean recycling approach, producing high-quality polymer melts even from contaminated post-consumer material – reaching virgin-like quality levels in many applications, including food contact.
The extrusion system is based on a specifically engineered screw design that not only ensures efficient melting and homogenization, but also supports intensive degassing and melt decontamination. This allows stable processing of materials with elevated moisture content, volatile contaminants, or low bulk density.
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Functional principle of the self-cleaning, process-constant Rotary filtration system RSFgenius |
Melt filtration based on Gneuss Rotary technology ensures continuous, process-stable removal of solid contaminants. The fully automatic system operates without process interruption, even under fluctuating input conditions and high recyclate shares.
Extrusion and filtration systems can be implemented either as standalone upgrades or as an integrated solution. System configuration is tailored to specific objectives – such as increasing recyclate throughput, stabilizing product quality, or enabling food-contact compliance.
Due to their compact design, integration into existing lines typically requires minimal modification of the surrounding infrastructure.
Summary
Increasing recyclate usage is both an economic necessity and a regulatory requirement. The key challenge lies in ensuring consistent product quality despite fluctuating input materials.
Gneuss addresses this with tailored retrofit concepts based on a Super-Clean recycling process – enabling reliable processing and high-quality output, up to and including food-contact applications.
