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Inline Recycling for Thermoplastic Materials: the HYBRID System from SIKOPLAST
Modern spunbond lines run fast and produce correspondingly large quantities of waste: edge trim at high-speed winders, start-up rolls, damaged rolls, loose waste from several parallel lines. Anyone processing all of this offline is fighting logistics, intermediate storage and material quality losses.
The HYBRID system from SIKOPLAST returns all types of waste simultaneously as melt directly into the production extruder: edge trim directly from the winder, roll goods including master rolls and loose waste. Even with high-speed winders at speeds exceeding 1,500 m/min.
The product range includes standard systems with material throughput capacities of 30 to approx. 250 kg/h per extruder. Multiple recycling lines can be combined.
How the HYBRID System Works
- Edge trim directly from the winder: The edge trim is extracted directly from the high-speed winder and fed to the system. Rewinding in the winder is eliminated.
- Roll goods and loose waste: Start-up rolls, damaged rolls and master rolls are fed in via the roll infeed of the cutting mill. Roll goods over 4.2 m in width can be processed depending on basis weight. Loose waste can also be returned.
- Pre-shredding: The cutting mill is ideally positioned in a separate room near the winder. The pre-shredded material is transported to the extruder silo by blower.
- Uniform feeding: An agitator integrated in the silo ensures uniform feeding of the extruder regardless of material type.
- Melting: In the extruder, the material is gently melted under exclusion of oxygen and without oxidation.
- Master-slave control: The once-set percentage return rate is kept constant in master-slave mode. When throughput changes in the production system, the HYBRID system is automatically adjusted.
- Direct melt feed: The plastic melt is fed directly into the production extruder. No intermediate granulate, no second melting process.
Material Spectrum and Applications
The HYBRID system is specially developed for spunbond production and covers all types of waste generated:
- Edge trim directly from the high-speed winder (>1,500 m/min)
- Roll goods including master rolls (width over 4.2 m processable depending on basis weight)
- Loose waste from the production process
- Start-up rolls and damaged rolls
Due to the contamination-free material feed, use in the hygiene and medical sector is also possible.
Plant Components:
1 Cutting mill · 2 Draw-in roller · 3 Cyclone with ionizier · 4 Infeed opening · 5 Fan · 6 Storage silo · 7 Fan · 8 Extruder with bunker silo · 9 Screen changers · 10 Melt pump · 11 Melt pipe · 12 Production plant
Master-Slave Mode: Fully Automatic Integration into the Production Process
The development of the HYBRID system focused on complete integration into the ongoing production process. The result is the master-slave mode:
A once-set percentage return rate is kept constant. If the throughput at the production system changes, for example due to speed fluctuations or product changes, the HYBRID system is automatically adjusted. No manual intervention, no production interruption.
In combination with the material- and energy-saving processing, this enables high return rates to be achieved without quality losses.
Greater Usable Winding Width as a Direct Productivity Advantage
The HYBRID system enables an increase in usable winding width in many cases. Since the edge trim is extracted directly at the winder and returned inline, the available winding width can be used optimally without having to reserve space for winder edge trim.
Edge trim return even at high-speed winders over 1,500 m/min
Simultaneous processing of all waste types: edge trim, roll goods, master rolls and loose waste
No intermediate granulate: direct melt feed into the production extruder
Master-slave mode: automatic adjustment of return rate when throughput changes
Increase in usable winding width through direct edge trim extraction at the winder
Use in the hygiene and medical sector through contamination-free material feed
HYBRID System vs. SIKOREX
| Criterion | SIKOREX | HYBRID System |
|---|---|---|
Edge trim speed | up to 600 m/min (special designs >600 m/min on request) | over 1,500 m/min, directly from the winder |
Waste types | Edge trim and/or roll goods | Edge trim + roll goods (incl. master rolls) + loose waste simultaneously |
Number of recycling lines | 1 line | Multiple lines combinable |
Roll width | Roll goods in standard widths | Over 4.2 m width processable (depending on basis weight) |
Automation | Fully automatic, both feeds separately controlled | Master-slave mode: automatic adjustment of return rate |
Hygiene/medical sector | Yes – contamination-free material feed | Yes – contamination-free material feed |
Productivity advantage | No rewinding of edge trim | Increase in usable winding width possible in many cases |
Throughput per extruder | 30–250 kg/h | 30–250 kg/h per extruder |
Typical target application | Standard spunbond and PE/PP film production | Modern spunbond production with high-speed winders, multiple lines or hygiene requirements |
FAQ
What distinguishes the HYBRID system from the SIKOREX?
The SIKOREX is designed for edge trim return up to approx. 600 m/min and a manageable number of waste sources. The HYBRID system extends this concept for high-speed winders over 1,500 m/min, simultaneous processing of all waste types and the operation of multiple recycling lines combined in one system.
Which industries is the HYBRID system suitable for?
Specially developed for spunbond production, also usable in the hygiene and medical sector. Wherever multiple waste types arise, high-speed winders are in use and a fully automatic return integrated into the production process is required.
What does master-slave mode mean?
In master-slave mode, the HYBRID system automatically follows the throughput changes of the production system. A once-set percentage return rate is kept constant, without manual intervention, even with fluctuating production speeds.
What throughput capacities are possible?
The product range includes standard systems with 30 to approx. 250 kg/h per extruder. Multiple recycling lines can be combined.
Can the HYBRID system be used in clean room or medical environments?
Yes. The material feed into the extruders is designed so that the production area is not contaminated. This also enables use in the hygiene and medical sector.
What roll widths can be processed?
Roll goods over 4.2 m in width can, depending on basis weight, be fed in via the roll infeed of the cutting mill.