KW Plastics Recycling pushes limits of ERF melt filter

By Bill Bregar
Senior Staff Reporter

Published: February 5, 2014 1:43 pm ET
Updated: February 7, 2014 9:35 am ET

Image By: Ettlinger North America Mike Diletti, managing director Ettlinger North America

Related to this story

Topics Sustainability, Recycling, Machinery

KW Plastics Recycling has become the largest North American customer for the ERF melt filter from Ettlinger Kunststofmaschinen GmbH—running 13 of the ERF250s on recycling lines in Troy, Ala.

The German company set up Ettlinger North America LP in Wheaton, Ill., near Chicago, last year. The North American business started in 2011, but did not have its own facility.

Traditional melt filters push the melt through screens that need to be flushed or changed frequently. The Ettlinger rotational filter is different. On the ERF, after coming out of the extruder, material enters a rotating, drum-shaped filter, which is continuously scraped clean by a knife. That cleans the filter constantly. An auger screw removes unmelted waste such as paper and aluminum.

KW Plastics is a major recycler of post-consumer plastic, including containers from high density polyethylene and polypropylene. CEO Kenny Campbell said the recycling operation is still finding out benefits from the ERF. "We found that our rates improved--better rates, better quality and you waste a lot less material," he said.

"The other thing is, it actually does a better job of filtration, we've found, than the conventional-type screens," he said. The high-quality recycled material goes through a pelletizer.

KW Plastics Recycling runs 26 extrusion lines, including single-screw and twin-screw extruders.

Recycled plastic accounts for nearly 90 percent of the total material KW runs. Ettlinger officials tout the ERF's ability to run heavily contaminated scrap plastic, and remove waste. Campbell said KW does thorough cleaning, washing and drying of its recycled plastic before it gets to the filter.

Campbell said the EFR just works better and more efficiently, with less hassle than traditional screen filters. "There are several advantages to the unit. One is it doesn't require any supervision. Two, the waste purge it generates is only a fraction, as compared to the other screen changers. It just doesn't waste much material at all."

Regular melt filters need backflushing to clean them out. That's not an issue with the ERF.

"One person could easily oversee half a dozen extrusion lines, or more, without any problem," Campbell said.

Initially, Ettlinger North America placed an ERF at KW for a 30-day trial. Campbell said he didn't know if the rotating filter would fit the recycler's needs. The supplier claims the ERF250 can run 4,400 pounds an hour. But Campbell said KW technicians found that number was conservative, and it can run at a much higher rate. The ERF also does a good job on stiffer fractional melt materials that do not flow as well, such as high density polyethylene from blow molded bottles.

And Campbell said the filter gives consistent melt pressure, which is important because KW Plastics Recycling compounds its material before pelletizing.

KW has ordered an ERF500, which links two filter drums in a common base with a single controller—essentially doubling the output of the 250 model. Ettlinger will deliver the 500 to KW in July.

Mike Diletti, managing director of Ettlinger North America, said KW will be the first customer in the United States to get an ERF500. He said KW hopes to get 13,000 to 14,000 an hour on the new filter, versus his current 6,500-7,000 an hour from the ERF250.


Comments

KW Plastics Recycling pushes limits of ERF melt filter

By Bill Bregar
Senior Staff Reporter

Published: February 5, 2014 1:43 pm ET
Updated: February 7, 2014 9:35 am ET

Post Your Comments


Back to story


More stories

Image

Austria's Greiner building a foothold in the US rigid packaging market

April 15, 2014 1:22 pm ET

Greiner Packaging International GmbH, one of Europe's largest makers of rigid plastic packaging, now wants to make its mark in the United States.    More

Image

SodaStream turns to PET for its new pre-measured flavor 'Caps'

April 15, 2014 1:40 pm ET

SodaStream International Ltd., maker of home beverage carbonation systems, is using plastic to bring more flexibility to its consumers.    More

JSW looks to improve equipment servicing in Europe through contract

April 15, 2014 11:09 am ET

Tokyo-based manufacturer of extruding machinery Japan Steel Works (JSW) has signed an agreement with a Dutch company to help it improve servicing on...    More

Image

US equipment firm buys Negri Bossi

April 14, 2014 1:58 pm ET

Italian plastics equipment major Sacmi Group's offerings are getting a U.S. identity. Sacmi has sold its plastics division to Kingsbury Corp., a...    More

Plastics recycling rates in Michigan will go up, if new initiative works

April 14, 2014 4:15 pm ET

Clean Tech, a unit of Plastipak Packaging Inc., expects to recycle about 6 billion plastic bottles this year and has an eye on 10 billion plastic bott...    More

Market Reports

Thermoformed Packaging 2014 Market Review & Outlook North America

This in-depth report provides analysis and discussions of economic and political conditions, market trends, legislative/regulatory activity impacting supply and demand, business opportunities and threats, materials pricing, manufacturing technology, as well as strategies being implemented by thermoformed packaging companies. In addition, there are reviews of 25 leading thermoformers in the packaging segment, assessing their growth initiatives and performance metrics over 10 years.

Learn more

Automotive Market Review and Outlook 2014 The Americas

This 75-page report features in-depth analysis of the automotive industry for the Americas. It includes discussions of market trends, legislative/regulatory activity impacting production and threats as well as design strategies being implemented by the major automakers. Detailed charts and data tables outline North American automotive production over the last five years.

Learn more

Plastics Building & Construction Market Review and Outlook 2014 with MS Excel chart data

This report provides in-depth analysis of the plastic building and construction market for North America, including discussions of trends, opportunities, threats and the latest developments in construction trends that impact plastics processors.

Learn more

Upcoming Plastics News Events

May 6, 2014 - May 8, 2014Plastics in Medical Devices 2014

May 12, 2014 - May 12, 2014Plastics News Brazil Pharma Summit

September 10, 2014 - September 12, 2014Plastics Caps & Closures 2014

February 3, 2015 - February 7, 2015Plastics News Executive Forum 2015

More Events