In the realm of post-consumer recycling, a compact footprint and high throughput are becoming critical. EREMA is addressing this need by advancing the INTAREMA® series, unveiling the 2021 model without a cascade at K 2025. Additionally, the growing demand for food and drink sustainable packaging leads EREMA to provide recycling systems that ensure the highest quality levels, actively aiding customers in the authorization process. A joint venture with Lindner Washtech enhances the value added in post-consumer recycling, securing a seamless end-to-end process.
The demand for post-consumer recycled pellets—specifically for sensitive applications such as food and drink packaging, cosmetics, and secondary packaging—is soaring due to legal requirements like the EU Packaging and Packaging Waste Directive (PPWR) as well as sustainability goals set by global brands. Consequently, these specifications amplify the requirements on production capacity and process stability within recycling facilities, ensuring high output volumes alongside consistent quality. EREMA offers reliable solutions tailored to these stringent standards.
Introducing the new INTAREMA® 2021 TVEplus®, now without cascade
Large plastics recycling operations require more than mere upgrades to individual components. As extruder screw sizes increase, so do the technological challenges. The launch last summer of the largest INTAREMA® system, boasting a throughput exceeding four tonnes per hour, underscores EREMA’s capacity for high throughput solutions. The newly upgraded 2021 model enhances system efficiency and reliability. “We have focused on the system and its individual components to ensure cost-effectiveness and process reliability on this scale,” states Markus Huber-Lindinger, Managing Director at EREMA.
At the K show, EREMA will present the INTAREMA® 2021 TVEplus®, which features a two-meter diameter preconditioning unit (PCU) and a 212-millimeter extruder screw. This system introduces a single end-to-end extrusion unit, offering a throughput of up to 3.5 tonnes per hour while maintaining a compact footprint of just 15.1 x 3 meters—over two meters shorter than the previous cascade setup. This innovative design also lowers melt temperatures, reduces energy consumption, and minimizes maintenance needs.
The latest 2021 model leverages TVEplus® and EREMA PCU technology to produce even higher quality recycled pellets. The Counter Current® technology plays a vital role, continuously supplying the extruder with preheated material that is 5 to 15 degrees Celsius warmer than conventional cutter compactor systems. This technological advantage facilitates gentler processing of the melt, resulting in reduced shearing and eliminating the need for additional particle size reduction. Consequently, impurities can be effectively extracted by the melt filter, a key element of this new development. “Thanks to our latest innovation in filtration, we have successfully implemented this system on this scale. We will demonstrate this innovation live at K 2025,” adds Markus Huber-Lindinger. The system is also compatible with DuaFil® Compact technology for enhanced filtration efficiency.
The ReFresher control system: Now networked with the PLC
Maintaining high recycled pellet quality is crucial for food and drink sustainable packaging. Recyclates for food packaging must fulfill stringent requirements established by both European and American food safety authorities. EREMA has initiated numerous approval projects, collaborating with customers to secure positive Non Objection Letters (NOL) from a US authority for HDPE, PP, and LD/LLDPE. Ongoing approval proceedings, especially in Europe, are a testament to this commitment. “A key driver of these projects is the new EU Packaging and Packaging Waste Regulation (PPWR), which mandates 10% recyclate content in sensitive packaging and 30% in all packaging by 2030,” explains Clemens Kitzberger, Business Development Manager Post Consumer Recycling at EREMA Group. “We are confident that we will obtain these approvals using our technologies, and we leverage our expertise to support our customers throughout the process.”
Two critical prerequisites exist for food-grade applications: an input stream of at least 99% food packaging and technology capable of cleaning and decontaminating the input material. The integration of INTAREMA® TVEplus® RegrindPro® and the ReFresher reliably removes low-volatility substances and associated odors. “The novel aspect is that the ReFresher control system is now networked with our machine PLC,” notes Markus Huber-Lindinger. “The new visualization system integrates data from both systems, providing intuitive and detailed insights into the entire process chain.” Users can also access combined data and trend analyses through the BluPort® online platform.
EREMA and Lindner Washtech: Ensuring a balanced overall process
“One of the main success factors for consistent recyclate quality from post-consumer waste streams is the optimal coordination of each process step—from sorting and recycling to the final product,” states Clemens Kitzberger. Success hinges on a culture of knowledge transfer throughout the entire value chain.
To facilitate this, EREMA collaborates closely with strong partners, including those within its group of companies. The partnership with Lindner Washtech enhances operational effectiveness. While Lindner Washtech excels in preparing input materials through sorting and both cold and hot washing, EREMA ensures effective cleaning and decontamination through extrusion and filtration technology. This synergy results in high-quality recyclate with optimized energy use. A case in point is a project with Polymer Matters in Ireland, which has applied to the European Commission for food-grade approval. In this initiative, HDPE milk bottles from household recycling schemes are processed into rHDPE used for the creation of new milk bottles.
Attendees at this year’s K trade fair can explore the successful collaboration between EREMA and Lindner Washtech at the Edvanced Recycling Centre located in the outdoor area.
Edvanced Recycling powered by EREMA
Currently, the campaign Edvanced Recycling – EREMA Prime Solutions for Advanced Recycling showcases EREMA’s diverse advanced plastics recycling solutions. With over 40 years of experience and practical application expertise, EREMA systems consistently yield high-quality recycled pellets tailored to specific quality specifications—ranging from food and drink packaging to straightforward applications. Edvanced Recycling illustrates EREMA’s commitment to working collaboratively with customers to sustainably elevate the use of recycled materials in new plastic products. For more information, visit edvanced.erema.com.
Learn more and visit EREMA at K 2025: Hall 9, Stand: C09 and at the Edvanced Recycling Centre: Outdoor area, CE03.
