Extrusion machinery manufacturers Gneuss and Colines are collaborating with US-based ExxonMobil Signature Polymers to produce stretch film incorporating recycled content.
Films have some of the lowest plastic recycling rates globally. Recycling low density polyethylene (LDPE) and linear low density polyethylene (LLDPE) films remains challenging due to contamination and impurities. Conventional production lines often struggle to convert LDPE and LLDPE, even when it has undergone extensive mechanical processing. Polymer gels, black dots and inconsistent recyclate properties disrupt the extrusion process, causing unexpected shutdowns and poor quality film.
The collaboration between Colines, ExxonMobil and Gneuss aims to overcome these hurdles. By integrating ExxonMobil's PE, Gneuss's advanced RSFgenius self-cleaning screen changer,and Colines' flexible film production lines, the project aims to create cost-effective, high-quality films with recycled content.
ExxonMobil's team have trials combining post-consumer recycled material with the company’s Exceed Tough m3812 PE. The companies said the trials demonstrated a significant reduction in disruptive polymer gels and improved process consistency.
Gneuss's RSFgenius filtration system plays a crucial role, enabling continuous operation by removing impurities without pressure fluctuations. This technology allows extrusion lines to run longer, minimizing downtime, and maximizing efficiency.
Colines, an Italian manufacturer known for its cast and blown film lines, has tailored its systems to integrate Gneuss filtration technology seamlessly. Their production lines now offer more flexibility and customization for incorporating recycled content.
Colines and Gneuss already collaborated on extrusion equipment for handling recycled material in 2022.
The new collaboration has demonstrated that films containing 30 percent PCR content can be produced consistently without interruptions related to recyclate processing. Production runs have achieved a thickness of up to 10 micrometers, maintaining quality and consistency throughout.
To showcase their achievements, the partners will host individual demonstrations at Colines' facility in Novara, Italy, in early 2025.