Complete solution plastics

  • 1 Chopper fan
  • 2 Chopper fan on ground frame with noise protection hood
  • 3 Filter fan
  • 4 Chopper fan on platform with noise protection hood
  • 5 Material separator with two waste fractions for sorting
  • 6 Cartridge-type filter                                                                            
  • 7 Universal filter system
  • 8 Centrifugal separator
  • 9 Rotational drum filter
  • 10 Extruder

Deltoid develops cost-efficient, energy saving and environmentally friendly turnkey solutions for pneumatic waste management – Made in Germany.

This guarantees the minimisation of interface problems, as well as a smooth total process.

 

Cost efficiency through maximum flexibility and reliability

Today in the plastic foil industry, a wide variety of foil types, foil thicknesses and edge strip widths must be produced with maximum flexibility and with minimal setup times.

Ever increasing environmental and quality requirements in the recycling process required unmixed waste sorting even in production facilities. This development shows that sorted production waste recycling is a perfect example for resource efficiency and economic value.

In recent years, the average machine speed for foil cutting systems and winding machines has increased significantly. Similarly, the amount of trimmings increased in this same time / period. An overview over the total waste at all cutting and winding machines plays a decisive role here.

 

Scope of performance

Example

Foil cutter facility Old
Machine speed 600 m/min
Plastic foil 8 µ bis 60 µ
Thickness 1,5 g/cm3
Edge strip (Amount x Width) 2 x 80 mm, max.
Edge strip waste 518 kg/h
Foil cutter facility Modernised
Machine speed 1000 m/min
Plastic foil 8 µ bis 60 µ
Thickness 1,5 g/cm3
Edge strip (Amount x Width) 2 x 80 mm, max.
Edge strip waste 864 kg/h
Extra waste 346 kg/h

 

These extra quantities of waste must not only be pneumatically gathered and transported, but also processed further, e.g. in the agglomerator, the waste container, silo or filter system.

To minimise the risk of a possible loss of production, parts of the edge strip waste system must be modernised or re-designed.

Here, it is extremely important to look at the whole extraction system. The demand for maximum availability, production flexibility and economic efficiency places the highest demands on the optimal dimensioning and design of the total system, right from the suction nozzle to the filter system with a heat recovery system.

 

A task that Deltoid has successfully been devoting itself to for decades.

Energy cost savings

Deltoid extraction systems offer multiple advantages here – modular, safe, flexible.

The modular and redundant designed Deltoid complete systems can be integrated into a machine data logging system (e.g. Hydra-Manufacturing-Execution-System (MES)). This way, the performance of the extraction system is automatically set up for the respective production process with the use of state-of-the-art technology.

In case of production grade changes, the diverter valves at the end of the feed pipe automatically switches to the required waste fraction.

This not only saves setup times, but also ensures unmixed production waste sorting while simultaneously reducing energy costs.

 

The producer therefore achieves high prices for his sorted plastic foil waste, while ensuring a significant increase in quality in the further recycling process.

This simple and cost-effective method of separating a wide variety of foil alloys stands for higher energy efficiency, cost-efficiency and short amortization times for modernisations or new investments. The ROI (Return On Invest) is thus achieved much sooner.

Operating costs

Lowering operating costs through intelligent heat recovery

Generally, the transported air from the pneumatic extraction system is not further used. The released transport energy / process warmth from waste transportation is usually directed out into the air, unused.

In order to ensure a balanced air quality in the production rooms, it can be important for the extracted air amount to be re-directed into the system. This can, for example, take place using a cross-flow heat exchanger, enabling up to 80% of the outgoing energy in the air to be regained.

The yearly operating costs / investment costs for external ventilation systems can thus be significantly reduced.

 

Quality

Clean cut, quality made visible

For completely wound coils the quality of the cut is directly connected to the cutting and extraction process.

A methodical mechanical and electrical coordination of the extraction system with the cutting machine is the prerequisite for optimal pneumatic gathering of the edge / trimmings.

Thus, the early project planning is already decisive for the long-term high production quality of the completely wound coil. At the same time, the facility operator is equipped with the maximum flexibility for the production of a wide variety of tape und foil types at differing winding speeds. The perfectly designed extraction system rules out the need for after-treatment of the coil.

 

Pictures