Saving costs through in-house recycling – Starlinger recycling

Starlinger recycling  Starlinger recycling  Starlinger recycling  Starlinger recycling  Starlinger recycling  Starlinger recycling

Saving costs through in-house recycling 

Starlinger recycling

Written by: Starlinger

Starlinger (know more)

Starlinger recycling technology is a division of Starlinger & Co GmbH, world market leader in the field of machinery and complete lines for woven plastic packaging production. For 30 years, it has been providing machinery solutions for the recycling and refining of a wide scope of plastics. Starlinger & Co talks about saving costs through in-house recycling, thereby improving efficiency in the operational cycle and contributing eventually to sustainability.

During the highly complex process of nonwoven fabric production waste occurs along the entire production chain-from start-up waste and off-spec material all the way to conversion scrap. Converting it in-house into a secondary resource helps nonwoven producers to cut down production costs by reducing their waste and raw material expenses.

Turning production scrap into a valuable secondary resource

Nonwovens consist of different polymers and polymer mixtures, have different viscosities, and type and amount of contaminations and required filtration fineness vary a lot. Due to the fact that nonwoven production waste comes in different shapes it is necessary to recycle it into pellets to make it suitable for reuse. For this, high quality is decisive: a production stop caused by less than perfect regranulate is costly and jeopardises the economic benefits of processing and reusing the production scrap.

The lack of quality control in case of tolling recycling very often prevents nonwoven producers from using recycled material. In-house recycling, on the other hand, helps a nonwoven manufacturer to control the quality of the regranulate through one’s own materials management. To ensure the production of high quality regranulate-which is a prerequisite for improving cost efficiency and the stability of the production process-an analysis of the input material and the right choice of equipment is paramount.

Successful examples of in-house recycling

Waste reduction, cost saving, sustainability: already more than ten years ago, these were three major reasons why nonwovens producers decided to recycle their production scrap. In 2003 and 2004, Starlinger recycling technology installed two of their first recycling lines for nonwoven production scrap at the nonwovens producers Don & Low, a member of Thrace Group in Great Britain, and Softbond in Argentina. In 2014, Global Nonwovens, India, made a Starlinger recycling line part of the equipment in the new nonwovens production plant that has been set up in the Mumbai region.

“We aimed to recover the cost of polypropylene by re-consuming the scrap in-house or selling the recovered waste in pellet form to consumers in the industry,” said Keith Galloway, general manager at Don & Low Ltd Nonwovens. “Second, by recycling we can reduce or even eliminate the amount of polypropylene waste that goes to landfill.” he added. Alessio Romanelli from the general management of Softbond confirmed this.

“Our target was to add value to the scrap from our main production lines. We use about half of the recycled polypropylene again in our mainproduction process and the rest we sell to local injection moulding companies,” he said. Both companies were able to meet the strategic targets by achieving cost saving for the company and its customers, and meeting the set environmental goals. According to Don & Low, the latter have become increasingly important: some of their customers specifically ask for recycled content in their product, a requirement Don & Low can meet without problems.

Sustainability was also one of the reasons why Global Nonwovens decided to include a recycling line in the setup of their new nonwovens production plant in Nashik, Maharashtra. “It improves efficiency in the operational cycle and contributes to sustainability,” the company said, and added that “with the effective utilisation of resources in mind, recycling is an important factorregarding the internally generated waste.”

The challenge: Recycling different types of nonwoven scrap

The range of nonwovens scrap is wide, and its shape varies greatly. To make it suitable for reuse, it is necessary to recycle it into pellets like virgin resin. The quality of the regranulate, as mentioned earlier, is very important: a production stop caused by inadequate regranulate is too costly, and jeopardises the economic benefits of recycling and reusing the production scrap.

Softbond manufactures polypropylene nonwoven cloth in various weights in a spunbond process and recycles almost all of its production scrap. The Starlinger recoSTAR universal 65 recycling line installed at their production facility is running around the clock, seven days per week. The nonwovens scrap is fed loose via a conveyor belt into the single-shaft cutter. The line produces 3,000 kg of polypropylene regranulate per day in offline operation. Softbond reprocesses between 30 tonnes and 40 tonnes of the recycled material in the nonwovens production process; the rest they sell on the market.


Don & Low, a producer of woven and nonwoven polyolefin technical textiles for the construction, agriculture, industrial, medical and consumer sector, also recycles all of its polypropylene spunbond scrap. It stems from nonwoven products made for applications like construction, furniture and bedding, carpet tile backing, and also includes composites that contain polypropylene materials other than spunbond.

The recoSTAR universal 65 in use at Don & Low is equipped with a reel feeder that is directly mounted on the single-shaft cutter. Different types of nonwoven scrap in different colours and sizes are processed; a master batch dosing unit adds the final colour for the regranulate in the recycling process, depending on the colours of the input material and the required final colour. The line is in operation five days per week on a three-shift system and produces high-quality regranulate with very little melt shift at a rate of 120 kg per hour.

“Depending on applications and physical specifications of the product, we can add up to 50 per cent recycled content to our spunbond lines without loss of conversion efficiency,” Galloway explained. Recycled material which is not used in the nonwovens production process is sold to converters for downstream products such as plant pots.

Global Nonwovens, in turn, caters to the hygiene sector and produces different types of SS (spunbond-spunbond) and SMS (spunbondmeltblown- spunbond) fabric. The recycling line installed at Global Nonwovens is a recoSTAR universal 105 VAC. It is equipped with a nip roll feeder and features an additional dosing unit for compounding-an option for value-adding-as well as a corresponding big bag unloading station. The production output ranges between 380 – 480 kg per hour. The line processes spunbond and spunbondmeltblown- spunbond polypropylene production scrap in the weight range from 40 – 200 g/m. Global Nonwovens reuses part of the recycled granulate in other business areas and sells the rest on the market.

Technology: Vacuum treatment, fine filtration, pelletising

It’s all in the melt: to ensure high-quality regranulate, Starlinger recycling systems are equipped with an extruder vacuum unit. It extracts volatile contaminants-spin finish, for example-and reduces viscosity loss in the melt. A variety of melt filtration systems ensure clean, high-grade melt: melt filters with and without backflushing, power backflush filters and continuous rotation filters are the most common. The choice of filter type and size depends on the type and amount of contaminants. A specially designed cascade filtration system enables very fine filtration down to 25 ?m to meet the high requirements in the fibre industry.

A choice of pelletising equipment can be supplied, depending on viscosity, preferred shape of regranulate, and required grade of automatisation. Optionally for PET/PES, crystallisation equipment and solid-stating reactors for IV (intrinsic viscosity) increase are available.

Starlinger recycling  Starlinger recycling  Starlinger recycling  Starlinger recycling  Starlinger recycling  Starlinger recycling

All the Plastic Ingredients at a Glance – Plastic Ingredients

Plastic Ingredients  Plastic Ingredients  Plastic Ingredients  Plastic Ingredients  Plastic Ingredients   Plastic Ingredients

All the Plastic Ingredients at a Glance

Plastics would not exist without additives. “Only diverse ingredients make useful materials of polymers”, explains Oliver Kutsch, managing director of the market research company Ceresana: “Additives facilitate the processing of plastics, protect against heat and UV rays, and expand the range of properties.”

Plastic IngredientsCeresana analyzed the complete world market for all major plastic additives in one study for the first time: fillers, plasticizers, pigments, flame retardants, stabilizers, impact modifiers, lubricants and slip agents, antioxidants, blowing agents, as well as other plastic additives.

Bright Prospects for Manufacturers

Global demand for plastic additives amounted to approx. 31.5 million tonnes in 2016. More than half of this amount was processed in Asia-Pacific. North America ranked second at a large distance.

Plastics increasingly replace other materials such as wood or metal. Therefore, demand for plastic additives will continue to increase: According to the demand volume and price development, Ceresana expects revenues to rise to about US dollar 60 billion until 2024.

The latest study of Ceresana examines the respective development of particular plastic additives in the 16 most important countries in detail.

Construction Industry Is the Major Consumer

Plastics are safe, reliable, light, and cheap: these characteristics lead to a growing use in the construction industry. Furthermore, plastics are increasingly the first choice regarding the thermal insulation of buildings.

The construction industry has to be convincing in many disciplines, for example efficiency, quality, environmental and fire protection. Hence, the highest amount of plastic additives worldwide is utilized in this application area.

The second highest amount of plastic additives is processed in the segment packaging. Plastic packaging becomes more and more popular since it is light, easy to handle, microwavable, and visually appealing.

It is possible to recognize the contents easily and the products remain preserved and rich in flavor for a long time. Ceresana also forecasts a continuously rising demand for plastic additives in this application area.

In this study, the use of additives in various plastic types is examined in more detail, that is, in polyethylene, polypropylene, polyvinyl chloride, polyurethane, engineering plastics, and other plastics.

Since PVC is a brittle, hard, and white material, the worldwide highest amount of additives is applied in this plastic type to adapt it to diverse applications.

Fillers Account for the Highest Demand

Fillers are the type of additives that is most frequently processed in plastics. Plasticizers and pigments rank second and third. More than 16 million tonnes of fillers were utilized for plastics in 2016: Fillers increase the volume of the mixture of materials without altering the main characteristics.

The production of highly filled plastics with properties tailored to meet the exact needs of individual consumers is rising as well: These highly filled plastics contain up to 85% of fillers, possess excellent mechanical properties and are even more cost-effective than conventional materials in many cases.

Plasticizers are substances that are added to plastics to improve elasticity, softness, and flexibility for processing and use.

Manufacturers of PVC account for by far the highest share of global demand for plasticizers. They are, for example, used for the production of profiles for windows or doors.

The Study in Brief:

Chapter 1 provides a thorough presentation and analysis of the market for plastic additives including forecasts up to 2024: Development of demand and revenues is given for each region.

Chapter 2 examines 16 countries individually. Country-specific demand, demand per additive type, additive demand per plastic type as well as revenues are depicted. Furthermore, demand in the particular application areas is analyzed.

Chapter 3 deals with the detailed examination of the application areas of plastic additives. Information is given for the six segments packaging, construction, transportation, electrical and electronics, industrial products, and other applications. This chapter examines the demand per country split by the respective sales market.

In Chapter 4, the types of plastic additives are depicted individually: fillers, plasticizers, pigments, flame retardants, stabilizers, impact modifiers, lubricants / slip agents, antioxidants, blowing agents, and other plastic additives. Demand development of the individual plastic additives per country are examined.

Chapter 5 provides useful company profiles of the largest producers of plastic additives, clearly arranged according to contact details, turnover, profit, product range, production sites, and profile summary.

Extensive profiles of 69 manufacturers are given, including BASF SE, Chang Chun Group, Clariant International Ltd., DuPont (E.I.) De Nemours, Evonik Industries AG, Exxon Mobil Corporation, Huntsman International LLC, Imerys Graphite & Carbon, Lanxess AG, and Vanderbilt Chemicals, LLC.

About Ceresana

Ceresana is an internationally leading market research and consulting company for the industry. For 15 years, Ceresana has been supplying several thousand customers from 60 countries with up-to-date market intelligence.

Extensive market knowledge creates new prospects for strategic and operational decisions. Ceresana’s clients profit from implementation-oriented consulting services, tailor-made single-client studies and more than 100 independent multi-client market studies. Ceresana’s analysts are experts on the following markets: chemicals, plastics, industrial goods, and packaging.

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Teknor Apex polyamides improve processability – Teknor Apex polyamides

Teknor Apex polyamides  Teknor Apex polyamides  Teknor Apex polyamides  Teknor Apex polyamides

Teknor Apex polyamides improve processability against standard glass-filled compounds

by John Carlon

by John Carlon

Global PET Blow Molding Machines Market 2017 – PET Blow Molding Machines

PET Blow Molding Machines 

Global PET Blow Molding Machines Market 2017- Krones AG, Sidel, SMF Germany, Aoki Technical Laboratory, Inc.

PET Blow Molding Machines The Global PET- Blow Molding Machines Market 2017 examines the performance of the PET- Blow Molding Machines market. It encloses an in-depth judgment of the PET -Blow Molding Machines market state and the competitive landscape globally. This report analyzes the potential of PET- Blow Molding Machines market in the present and the future prospects from various angles in detail.

The Global PET-Blow Molding Machines Market 2017 report includes PET- Blow Molding Machines industry volume, market Share, market Trends, PET -Blow Molding Machines Growth aspects. A wide range of applications, Utilization ratio, Supply and demand analysis are also consist in the report.It shows manufacturing capacity, PET- Blow Molding Machines Price during the Forecast period from 2017 to 2022.

Manufacturers Analysis and Top Sellers of Global PET- Blow Molding Machines Market 2017:
1 Krones AG
2 Sidel
3 SMF Germany
4 Aoki Technical Laboratory, Inc.
5 ASB International Pvt. Ltd.
6 KHS GmbH
7 Sipa S.p.A.
8 Bekum America Corporation
9 Jomar Group
10 Newamstar Packaging Machinery Co., Ltd.
11 Dongguan Tongsheng Machinery Co., Ltd.
12 Quinko Fujian Machinery Industrial Co., Ltd.
13 Hongkong Tongsheng Group
14 Zhejiang ZIQIANG Machinery Co., LTD

PET -Blow Molding Machines Market Analysis: By Product
Low Density Polyethylene (LDPE)
High Density Polyethylene (HDPE)
Polyethylene Terephthalate (PET)

PET -low Molding Machines Market Analysis: By Application

At the beginning, the report covers the top PET-Blow Molding Machines manufacturing industry players from regions like United States, EU, Japan, and China. It also characterizes the market based on topographical regions.

Further, the PET-Molding Machines report gives information on the company profile, market share and contact details along with value chain analysis of PET- Blow Molding Machines industry, PET- Blow Molding Machines industry rules and policies, circumstances driving the growth of the market and compulsion blocking the growth. PET -Blow Molding Machines Market development scope and various business strategies are also mentioned in this report.

The PET- Blow Molding Machines research report includes the products that are currently in demand and available in the market along with their cost breakup, manufacturing volume, import/export scheme and contribution to the PET- Blow Molding Machines market revenue worldwide.

Finally, PET -Blow Molding Machines market report gives you details about the market research findings and conclusion which helps you to develop profitable market strategies to gain competitive advantage.

Unicharm chooses Diaper Recycling Technology – Unicharm Diaper Recycling Technology

Unicharm  Diaper Recycling Technology  Unicharm  Diaper Recycling Technology  Unicharm  Diaper Recycling Technology

Unicharm chooses Diaper Recycling Technology

JAPAN – Diana Unicharm, part of the Unicharm Group in Japan, is to install new recycling operations from Diaper Recycling Technology to process factory waste and negating the need to this waste stream to landfill

Unicharm Diaper Recycling Technology

Diaper Recycling Technology team



Diaper Recycling Technology Commissions New Central Recycling Process

Makers of the new low energy air-less diaper recycling process commission central recycling process at 500 KG/hour @ 15.5 KW

Diaper Recycling Technology, a technology company solely focused on advanced diaper recycling solutions, successfully commissioned a new central recycling process capable of processing 500 KG/hour per module while achieving breakthrough energy requirements.

Melvin Tan, operations manager of Diaper Recycling Technology, says:  “The team has worked hard to achieve these new milestones and we are all appreciative of the hard work and dedication of the engineering and process teams to achieve this significant milestone.

Part of our drivers to develop the new air-less process were not only to benefit our end-customers but also to benefit the environment.”

Martin Scaife, managing director of Diaper Recycling Technology, comments: “We are very happy with the new process performance, not only the reduced power requirements but more significantly the purity of the material streams allowing risk free pulp re-feed back into the core-former and the high value re-sell of the PE/PP material stream.

We also have to thank the R&D team on their newly developed SAP separation process. This breakthrough is key to ensure that the SAP can be re-used back within the production process without detrimental effects to the end-user.
The new process not only ensues a pure SAP stream but as the process operates without passing SAP through fans the ever critical SAP outer cross-linker surface is retained thereby ensuring no negative product impacts.”
Unicharm  Diaper Recycling Technology  Unicharm  Diaper Recycling Technology 

Sabic will launch the production of olefins in the Netherlands this weekend – Sabic olefins Netherlands

Sabic olefins Netherlands  Sabic olefins Netherlands  Sabic olefins Netherlands  Sabic olefins Netherlands 

Sabic will launch the production of olefins in the Netherlands this weekend

Sabic olefins Netherlands MOSCOW ( Market Report ) – Sabic Europe, a subsidiary of the Saudi company Sabic in Europe, plans to launch production of olefins at this weekend cracking unit No. 3 in Geleen, the Netherlands, afterwards for scheduled preventive maintenance, ICIS reported. Press secretary of the company.

“We had some difficulties in restarting our cracking unit No. 3 after repairs, but now we have solved these problems and are planning to launch this weekend,” the spokeswoman said.

Restart after a scheduled repair, which began in March, was originally expected in the second half of May.

Sabic Europe has two cracking units on this site, which usually close for scheduled repairs every six years. This cracking unit with a capacity of 575,000 tons of ethylene per year was closed for repairs in early March. Initially, the restart was expected in the second half of May. The sources reported attempts to launch the cracker on May 24 and May 29.

Earlier it was reported that Sabic Europe on May 18 resumed the production of butadiene with a capacity of 130 thousand tons per year at the plant in Geleen (the Netherlands) after the planned preventive works.

Ethylene is the main raw material component for the production of polyethylene (PE).

According to DataScope of MRC, for the first four months of the year the total volume of external supplies of polyethylene (PE) to the Russian market grew by 3% compared to the level of 2016 and amounted to 160 thousand tons. Supplies of low-density polyethylene (HDPE) and ethylene-vinyl acetate (EVA) have risen dramatically.

Sabic Europe (the Netherlands), includes three refineries in Europe: Geleen (Netherlands), Teesside and Wilton (Great Britain) and Gelsenkirchen (Germany).

Sabic is a diversified company producing chemical products, industrial polymers, fertilizers and metals.

It is the largest state company in Saudi Arabia. Sabic is currently the world’s second largest producer of ethylene glycol, the third largest producer of polyethylene, the fourth largest producer of polypropylene.

Author:   Anna Larionova


Sustainability and Performance: high quality fashion yarn – Sustainability Performance fashion yarn

Sustainability Performance fashion yarn Sustainability Performance fashion yarn Sustainability Performance fashion yarn

Sustainability and Performance: high quality fashion yarn

In the new book NEO-MATERIALS IN THE CIRCULAR ECONOMY – FASHION, RadiciGroup presents its reduced environmental impact product range Solution-dyed polyester, recycled polymer polyester and biobased polyamide are some of the kinds of low environmental impact yarns produced by RadiciGroup specifically for the fashion industry.

Sustainability Performance fashion yarnThe fashion world is finally addressing sustainability and looking for materials that are not only beautiful and strong, but also sustainable.

The RadiciGroup product portfolio meeting these new market requirements is described in the recently published book Neomaterials in the Circular Economy – Fashion, available now in bookshops in both Italian and English versions.

The book is edited by Marco Ricchetti in collaboration with Blumine Srl and the Italian sustainable fashion social network Sustainability-lab.

The section about the Group, “RadiciGroup and the Future of Synthetic Fibres”, written by Aurora Magni, appears in the first chapter of the book and can also be read on the RadiciGroup website (click here).

Moreover, the book as a whole offers numerous in-depth articles to provide an overall picture of the direction of the fashion industry.

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