Gneuss at Plastics World Expo 2023: New OMNI Recycling Systems for post-consumer and industrial plastic waste recycling

New OMNI Recycling Systems for closed loop recycling of PET, PS and polyolefin post-consumer reclaim

OMNI Freigestellt

Fig.1.: OMNI Recycling System with 3C Rotary Feeder, MRS Extruder, Rotary Melt Filter RSFgenius, Online Viscometer VIS and downstream pelletising

With its innovative OMNI recycling systems, Gneuss offers efficient solutions for today's and tomorrow's recycling requirements. The new OMNI recycling systems consist of a variety of machines from Gneuss‘ portfolio, customised to a specific material and application, utilising Gneuss‘ established devolatilisation and filtration technologies. The OMNI line is equipped with a 3C Rotary Feeder, an MRS Extrusion System, a fully automated RSFgenius melt Filtration System, a VIS online viscometer and downstream equipment.

Polymer reclaim such as fiber waste, thin film or other low bulk density waste is fed into the Gneuss 3C Rotary Feeder. PET post-consumer and industrial waste does not require thermal pre-treatment. A conveyor belt feeds the material into the 3C Rotary Feeder, which cuts, compacts and conditions the material and feeds it directly into the MRS extruder.

The MRS extrusion technology in the OMNI recycling line is based on conventional single-screw technology, but is equipped with a multi-screw degassing section. The degassing section of the patented process unit consists of an enlarged single screw drum with a series of satellite screws that rotate in the opposite direction of the extruder barrel, creating a very large melt surface area and ensuring very rapid surface exchange. This provides unprecedented melt phase degassing performance with minimal material stress. Multiple Letters of Non-Objection (LNOs) from the FDA, EFSA compliance and local approvals in Latin America confirm the high decontamination performance of the technology.

After passing through the MRS extruder, the polymer melt is filtered by the highly efficient, self-cleaning Gneuss RSFgenius melt filtration system. This system ensures that fine filtration is possible without pressure or flow disturbances and with minimal polymer losses, even at high contamination levels. The RSFgenius works with an integrated backflush system for self-cleaning of the screens for very demanding applications and highest quality requirements. 

If the recycled material to be processed requires a particularly high decontamination and degassing performance, the OMNImax recycling system is used with an MRSjump extruder. This extruder has a longer, modified version of the Multi Rotation Section, which ensures both a longer residence time of the material and a disproportionately high surface area exchange under vacuum.

The OMNIboost recycling system is specifically designed to recycle PET waste. The integrated Gneuss JUMP polyreactor raises the IV value to the desired level within minutes. After leaving the MRS extruder, the polymer flows directly into the reactor in the melt phase, while the viscosity of the melt is tightly controlled. By controlling the vacuum, residence time and surface exchange rate in the reactor vessel, the viscosity is adjusted to the desired level. With a consistent set viscosity, the melt can then be fed directly into the production process. By ensuring that the polymer remains in the melt phase from the extruder to the final processing stage, the OMNIboost recycling process is the fastest and most efficient way to recycle PET when viscosity increase is required.


Fig.2: OMNIboost Recycling System with 3C Rotary Feeder, MRS Extruder and polyreactor JUMP