The art of recycling
lies in technology
Our technology is unique in the Czech Republic in terms of what it is capable of. We have modern facilities and are always adapting our technology to current challenges on the waste market.
The Plastic Union group’s recycling technology is unique in that this is the only company in the Czech Republic to process composite plastics from yellow bins in such a way that they can be separated into single-type materials. This results in single-type, homogenised regrind and regranulate of up to 99% purity, i.e. it contains only negligible traces of other materials. Thanks to its modern recycling technology, the group can handle plastics from start to finish: purchase, manual sorting, grinding, dirt removal by washing, separation by type and colour, regranulation, and subsequent sale of the resulting regranulate.
First, the incoming material is manually sorted on a conveyor belt. Here, workers help to remove impurities from the material. One of the first pieces of technology involved in the process is a magnetic separator, which removes all metallic impurities, including any that have escaped visual detection.
The next stage is crushing. This relies on a large dredge crusher capable of crushing large pieces. The output is plastic regrind with granulation of 150 mm, in which metallic impurities are again separated and then pre-sorted by NIR technology machine to polypropylene, polyethylene and other plastics with no usage at this time. It is moved via a conveyor system towards the washing line.
The technology meets the highest demands placed on the ecology of operation with its own specialised wastewater treatment plant. The unique system of multiple washing removes all dirt and any residues of cleaning agents that may have remained in plastic containers. At the start of the wet process, it first grinds the plastic to a granulation of 25 mm.
After washing, the mixture is divided by a basic sedimentation method into floating lighter types of plastic, i.e. polypropylene [PP] and high-density polyetylene [HDPE], and non-floating heavier types of polymers, i.e. especially polystyrene, PET, PVC and ABS. Excess water is removed from the still wet plastic regrind, by now divided into floating and non-floating parts. The regrind is then dried with the help of a centrifuge and air to the moisture required for the next part of the recycling process and cleaned with a dust and light particle separator.
The next part of the recycling technology is a device for the variable type-based separation of selected types of polymers. The input is dry material (with a maximum surface moisture of ≤2%) that has granulation to 10 mm and is free of metal particles. This equipment, which operates on the principle of NIR - ray reflection obtained from the surface of plastic fragments, allows material choice to be adjusted. Separation results in two types of regrind: polypropylene [PP] and high-density polyethylene [HDPE]. These market-ready materials can be further homogenised and granulated.
Plastic regranulate is the final stage in the ecological recycling and processing of plastic waste. The regranulation line is a technological unit for the processing of washed and dry regrind. The technological unit has a few homogenization silo installed at its entry point and an automatic storage system for the continuous feeding of the extruder.
The extruder is filled by an unmanned gravimetric dosing system, which can accurately dose up to three formula items to enrich (with fillers or additives) or colour the output granulate.
The extruder is fitted with a melt filtration system so that it can be continuously operated without any interruption in production. A liquid ring granulating set with rotary blades for hot granulate production is compactly connected to the mouth of the extruder chamber.
The produced granulate is carried by the water of a closed-circuit cooling system through an anti-corrosive vibrating screen. This cooling circuit features a basic used-water filter with heat exchanger.
The cooled granulate that has passed through the vibrating screen is then centrifuged in a centrifugal fan and transported to a filling station that has been installed for large-capacity transport bags to be attached to it.