Ettlinger Kunststoffmaschinen GmbH
Ettlinger is a family company founded 1983 in Augsburg, Bavaria. Our core competence is the development and manufacturing of high performance melt filters and injection molding machines. We are active worldwide with a subsidiary in Atlanta and representatives in all the major markets.
Ettlinger is recognized as one of the leading companies in high performance filtration with over 200 filters installed worldwide and more than 30 years of experience.
ECO Melt Filters: Polymer filtration one step ahead
The continuously operating ECO melt filter is suitable for filtering easy flowing materials such as PET and PA, virgin materials as well as plastic melts with low contamination content (max 1,5 %).
With its unique self-cleaning function the ECO filter is the perfect solution to reduce gels, black specks and other impurities in film, sheet and compound and to increase the availability of your production line.
The ECO can be integrated in almost any existing line, has a small footprint and is available in two different sizes.
How it works
The heart of the ECO melt filter is a rotating, cylindrical filter screen with a large number of conical holes. When melt flows through the filter, contaminants are retained on the outside of the screen. Contamination in virgin materials can be high-molecular and cross-linked particles from the polymerization process, gels or contamination due to temperature stress. In the recycling material the contamination can be wood, aluminum, paper etc.
With every revolution of the rotating filter screen a scraper cleans the filtration surface. The particles removed from the surface are continuously fed to a discharge shaft. The continuous cleaning and discharging avoids that contamination can build up on the filtration surface and increase the pressure, which means that particles, like gels and any other elastic contaminants, cannot be pushed through.
Due to the long lasting filter screen (weeks or months depending on the application) ECO ensures a continuous operation with a constant pressure on inlet and outlet side.
The system is completely closed so that the melt has no contact to the atmosphere. The melt flow is consistent without dead zones to avoid degraded polymers.
ECO allows using up to 100% recycling materials with an excellent quality of the final product and has an excellent mixing and homogenizing effect on highly filled melts.
Last but not least this melt filter requires very little operator assistance and has lowest maintenance costs.
An application example: Retrofit of an existing PET film line
Initial situation: PET multilayer sheet line with a multi and monolayer thermoforming PET sheet production for food packaging with a max throughput of 2500 kg/h. The material was a mix of virgin PET and PET bottle flakes, as well as 100% bottle flakes.
After an extruder stop it would take 1-2 hours to get back into in-spec production. The increasing pressure due to the clogging of the screen with contaminant would cause black specks in the sheet. Furthermore black specks were caused during the back-flushing and the screen change.
The ECO 250! The constant pressure level lasting 4 to 6 weeks helped reducing the amount of black specks to an acceptable level. On top of this, there was a considerable scrap reduction when starting the line (about 50%) and during operation as the ECO is not causing any black specks internally.
An application example: retrofit of an existing PET strapping line
Initial situation: PET strap extrusion line with PET strapping tape production for packaging with a maximum throughput of 800 Kg/h. The material was 100 % PET bottle flakes.
The screen bolt movement of the existing screen changer during back-flushing would cause an high amount of black specks. Furthermore, only a small contamination level could be processed and it was only possible to use very well pre-washed PET bottle flakes.
The PET strap was stretched and it happened too often that the strap tore off and caused a downtown of the line.
The ECO200! The start and the stop of the line were possible without any operator intervention on the filter for almost 8 weeks. The amount of stops related to the tearing off of the strap was considerably reduced and it was possible to use a cheaper material with higher contamination without any negative impact on the process but with a better final product.
ERF Melt Filters: Patented High Performance Filtration since 2004
The continuously operating ERF Melt filter, existing in 3 different sizes depending on the throughput required, is suitable for filtering plastic melts with a very high level of contamination. The machine effectively filters out paper, aluminum foil, wood, PET, nylon, rubber and silicone. The main characteristics of this fully enclosed system are the constant melt pressure, the extremely low melt losses and the very short contaminant retention times.
The typical applications are recycling, sheet and film extrusion.
How it works
A filter drum with a large number of conical holes rotates while the melt flowing through it from the outside towards the interior. The contaminants contained in the melt are retained on the filter surface and, after every revolution of the filter drum, are cleaned off by a scraper and fed to the exit screw.
Both filter drum and exit screw are driven by a dedicated servomotor, which ensure an accurate control. The speed of the filter drum and the exit screw can be separately adjusted, enabling the filter surface to be kept constantly free and clean and the melt loss to be reduced to a minimum.
Due to the long lasting filter screen the ERF ensures a continuous operation without any operator intervention.
Compared to any other filtration system, the ERF guarantees very low melt losses which enable a quick amortization of the initial investment. Furthermore, this filter works with a constant melt pressure downstream (+/- 2 bar), which is extremely important for the equipment after the filter. The system is completely closed so that the material will never be in contact with the atmosphere, which is important to avoid degradation of the material. The short retention time of the contamination on the filter surface helps avoiding contaminants as paper to burn and cause a bad odor in the final product.
ERF filters are suitable for processing all standard polyolefins and polystyrenes with the exception of PVC; they are designed to remove contaminants such as paper, aluminum, wood, silicones or high viscosity plastics from heavily contaminated material.
Some application examples are LDPE Packaging film with paper labels as contaminants (1-3 %), PP or ABS refrigerator scrap with rubber and wood contaminant (app. 3%), PS yogurt cup punching with Aluminum and PET, Household garbage (PE/PP) with paper, wood, aluminum and other unmelt polymers, Pipes with an aluminum inner layer with a contaminant content of 8-10%, HDPE Bottle caps with PET and Paper, PP/EPDM recycled bumpers with polish and rubber as contaminant, HDPE cosmetic and detergent bottles with paper and aluminum, EPS sheets, diapers and more…-
“srm” Injection Molding Machines
It was with injection molding machines that the Ettlinger success story first began, yet what is it exactly that makes them so unique? Our injection molding machines boast higher shot volumes at much lower footprint compared to conventional systems, yet require significantly less clamping force. They can consequently be equipped with smaller drives and consume up to 60% less energy than similar machines from competitors. Thanks to the two-stage injection unit with separate plasticizing and injection cylinder, our injection molding machines are capable of processing not only virgin but also recycled material or mixed plastics exceptionally efficiently.
Our machines are particularly suitable for the production of parts with high shot weights such as plastic pallets, fittings, or manholes weighing anything up to 130 kg or more
Some application examples
Injection Molding Machines for Pallet Production
Our injection molding machines are particularly suitable for pallet production because they can also process regrind or recycled material, so that relatively low clamping forces suffice even for complex pallet geometries with a closed deck.
Injection Molding Machines for Manholes
Our injection molding machines, featuring very high shot volumes of up to 180,000 cm3 in conjunction with energy-efficient hybrid drive technology, are particularly suitable for manufacturing large manhole systems. Our manhole systems have a modular structure comprised of an entrance cone, shaft ring, and shaft bottom with port openings for the pipes; they frequently have an overall height of several meters.
Injection Molding Machines for Fittings
Apart from the relatively low clamping forces, our injection molding machines also offer a high degree of variability for complex injection processes, which are often inevitable when manufacturing thick-walled fittings. These machines also have a large opening space with no tie bars for optimal accessibility from the side. As a result parts can be removed or the mold can be changed much faster and more easily, especially with large moldings.
Injection Molding Machines for Customized Solution
Traffic Systems: Our injection molding machines are equipped with a two-stage injection unit as standard, which separates the "plasticizing" and "injection" processes into two distinct sections and enables even challenging materials such as recycled soft PVC to be processed efficiently. To compensate for the long setting times of these very thick-walled moldings, our machines also have a rotary table with four stations that can hold several injection molded parts until they are ready for demolding, saving considerable time and money.
Injection Molding with integral ERF Filter: Our injection molding machines allow the filtration and injection molding processes to be combined in one piece of equipment. An ERF continuous melt filter is integrated between the extruder and injection unit for this purpose, enabling the contaminated melt to be cleaned in a single step. A separate repelletizing line with melt filtration can therefore be dispensed with. As a result of this, the material is processed much more gently and energy efficiently, while the footprint is smaller and the capital investment substantially lower.
Offshore: Our injection molding technology is also used as part of the process to manufacture oil and gas supply pipelines. The pipelines are built offshore on so-called laying vessels, where the individual steel pipe sections are fitted together and therefore have no protective or insulating layer at the ends. After the pipes have been welded the weld zone is over-molded with plastic using Ettlinger technology, to protect it from seawater damage and then lowered into the sea.
17.02.2017 | Königsbrunn , Germany
07.09.2016 | Königsbrunn , Germany
01.06.2016 | Königsbrunn , Germany
05.08.2015 | Königsbrunn , Germany
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15.07.2013 | Königsbrunn , Germany