Connected Systems for Optimum Plastics Recycling : Recycling 4.0 to be EREMA Plastic Recycling’s Focus at K 2016

At this year’s K 2016 exhibition in Dusseldorf, EREMA Plastic Recycling Systems is to focus on the Recycling 4.0 With CAREFORMANCE.

According to the company it is set to herald the age of Recycling 4.0 as the first in the plastics recycling industry to present a Smart Factory package for both recyclers and producers.

At the K 2016 show EREMA said that it will be building on its INTAREMA® technology presented in 2013, this time with its trade fair theme of "CAREFORMANCE – We care about your performance" to grow its pioneering role this year with Industry 4.0 applications.

"Building on the high degree of automation of the INTAREMA® systems we have developed a Smart Factory package which enables us to give our customers a clear competitive edge and make them fit for the future," explained EREMA CEO Manfred Hackl.

The company added that visitors to the trade fair will not only be able to experience CAREFORMANCE in theory, they will also see it live in action at the CAREFORMANCE Recycling Centre covering 480m2 in the outdoor area.

This is where an INTAREMA TVEplus 1108 with integrated Laserfilter can be found. It will be recycling some of the plastic waste from the K show live on site. The machine, quality and process data will be transferred in real time to the EREMA booth in Hall 9, Stand C05.

Besides the live recycling, visitors will be able to judge how convincing progress in the development of plastics packaging recycling is. The closed product loop from production to reuse will likewise be presented in live demonstrations.

The company added that the Recycling Centre will feature an extensive exhibition of products made with recyclate, showing how many branches of industry are committed to recyclate. The Recycling Centre will be opened at 11am on 19 October in the outdoor area (FG 09.1).

QualityOn package

The company explained that CAREFORMANCE consists of four components, with the INTAREMA® system forming the basis for the further Smart Factory applications.

In addition to the previous machine data, specially integrated sensors – the QualityOn package – can be used in future to record and evaluate MVR (Melt Volume Flow Rate) and colour.

The QualityOn package is said to enable recyclers and producers to make their recyclates with consistent quality in accordance with the special requirements of their customers and document them transparently using online data acquisition and analysis. Recipes recorded electronically can be compared with each other and modified.

re360

In order to make use of the vast amount of machine, quality and process data in a worthwhile and user-friendly way, EREMA explained that it has developed the MES (Manufacturing Execution System).

With re360 it is claimed to be possible to keep track of the productivity of an entire range of machinery in five modules.

"A key benefit of re360 is that it works independently of the plant manufacturer," saId Hackl. "Customers can integrate not only different systems but also their global production locations."

re360 gives also an overview of the capacities/stoppage times of the systems for management, documents key quality data of the recyclates for the location manager and informs the operator about upcoming maintenance jobs.

Spare Parts Online

Having been developed with customer requirements in mind, EREMA said that it has also developed a Spare Parts Online webshop.

Any upcoming maintenance work and the replacement of individual parts is said to be displayed in good time by re360. Spare parts can then be ordered directly via the online webshop to keep downtime as low as possible.

The customers' respective EREMA systems and previous orders are stored at Spare Parts Online.

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