Packaging

Energy-efficient blow molding with PCR

Wednesday 19. October 2022 - At K 2022, blow molding specialist W. MÜLLER is presenting a 3-layer extrusion unit that shows how the right combination of extruder and extrusion head turns used plastics into high-quality packaging. The system saves energy through a unique heating-cooling combination.

The processing of plastic recyclates places particularly high demands on machine technology. The use of post-consumer resins (PCR) is specifically challenging. At K 2022, blow molding specialist W. MÜLLER is presenting a 3-layer extrusion unit that shows how the right combination of extruder and extrusion head turns used plastics into high-quality packaging. The system saves energy through a unique heating-cooling combination.
At booth A38 in hall 14, W. MÜLLER EBM technology will be presenting a system specially designed for PCR processing at K 2022 in Düsseldorf from October 19 to 26. The material is melted by an S100/25D extruder and the PCR is embedded between two thin layers of virgin material. This ReCo3 process makes the use of PCR considerably safer and the blow-molded containers more visually appealing. In addition, the desired stability of the container can be implemented more precisely.
Managing Director Christian Müller explains: “We want to make the use of PCR in blow molding accessible to everyone. With this system, the former special case of recyclate processing becomes the standard.” The system has a screen changer in order to be able to carry out the change of the melt filter required for PCR processing quickly and safely.
Safe and energy-saving – innovative heating tapes
To make the use of recyclates even more energy-saving, W. MÜLLER has installed a special heating-cooling combination on the system. Manufacturer Keller, Ihne & Tesch has been dealing with electrical heating technology for 90 years. The heating tapes are made of aluminium instead of ceramic as usual. The metal is more stable, absorbs heat energy more quickly and releases it more quickly. Christian Müller is very impressed by the new development: “Our modified heating-cooling combination combines numerous advantages. We save around 2,000 watts, the energy is evenly distributed over the entire area, but the unit does not get hot on the outside, thus avoiding accidents. In addition, it is considerably more compact than conventionally heated heating tapes. “
Years of experience with recyclate
W. MÜLLER can look back on decades of experience in dealing with recycled plastics and is happy to pass them on to its customers. Technical Center Director Varinia Lück says: “PCR materials are new territory for many processors. Already in 2005 we gained experience with such materials from various manufacturers. We test the processability, the
Performance, support migration tests and help if there is a loss of mechanical properties, impurities, or processing problems. We are looking forward to many interesting technical discussions in Düsseldorf. “