Regranulation MachinePosted 2023-12-05
Henrik Johansson Kask, Production Manager at Emballator Mellerud, began the quest for a specialized machine nearly three years ago, foreseeing the need to revolutionize the waste management system at the factory.
“Our initial efforts involved using our own mills to reuse trims and scraps from our blow molding machines, effectively reintegrating them into our production process,” says Henrik Johansson Kask.
Although this method significantly reduced waste, it faced limitations when dealing with larger clumps and “dusty” residues, surpassing the capacity of existing machines, resulting in approximately 200 tons of waste annually.
To address waste management challenges and achieve more efficient reutilization, Emballator Mellerud AB established a close collaboration with the Swedish company Battenfeld. They aided in developing and implementing groundbreaking technology manufactured by NGR in Austria. The acquisition of this advanced solution occurred nine months ago, with installation in Mellerud in September.
After a meticulous and comprehensive testing phase, full operational capacity was achieved in October, led by NRG’s technician and electrician, Andreas Himmelsberger. Battenfeld’s experts, Michael and Kenneth Hiljemark, were responsible for further refining the process.
“This strategic collaboration and the implementation of advanced technology have been crucial in taking our next significant step towards more efficient and sustainable waste management in our production,” says Henrik.
Function and Workflow
The regranulation machine’s function involves a process where clumps of waste material are shredded into smaller pieces, fed into an extruder, and transformed into pellets through a series of complex mechanisms. The pellets pass through a cooled water bath for temperature control, undergo centrifugation for drying, and finally end up in a cyclone before being stored in an octabin.
Advantages and Sustainability Impact
The investment in the new regranulation machine has generated multiple benefits for production, enhancing the internal handling and transformation of a significant portion of waste into reusable material. The machine has not only increased efficiency in manufacturing processes but has also reduced carbon footprint.
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“The new regranulation machine marks a significant milestone in our pursuit of a more environmentally friendly and efficient production process and has, in many ways, redefined our approach to waste management and sustainability within the company,” says Henrik.