(Photo credit: Gneuß)

K Show Preview

Gneuss at K 2019: New Rotary Filtration System SFneos, second generation multiple screw extruder MRS and more

| Recycling technology | Gneuß Kunststofftechnik | Bad Oeynhausen | Germany

Gneuss Filtration Technology will exhibit several different models of their patented Rotary Filtration Systems at the K trade fair this year (Hall 9, Booth A38).


New SFneos along with several other filter models on display

Gneuss Filtration Technology will exhibit several different models of their patented Rotary Filtration Systems. These continuous filtration systems are characterized by a filter disk on which the screen cavities are located in a ring pattern. Screens can be changed on the part of the filter disk that is not active in the melt channel, while the production process continues to run without any interruptions or disturbances.

The new model SFneos was developed to combine the charactertistics of several older models into one simple and cost-efiicient solution, offering the following advantages:

  • Constant pressure guaranteed  – even during screen changes
  • Suitable for most types of polymers and viscosities
  • Compact design thanks to an enlarged active screen area
    (up to 2370 cm2)
  • Simple and safe handling and operation with several screens accessible for screen changes
  • Very cost effective thanks to its improved design

The SFneos is the ideal filtration system for applications that benefit from a continuous, pressure and process constant screen changer, but that don’t require back-flushing. The SFneos 90 on display has an active screen area of 260 cm2 .

Gneuss’ top model, the RSFgenius, operates with an integrated self cleaning system for very demanding applications and highest quality requirements. Screens can be automatically re-used up to 400 times and filtration finenesses below 10 microns/1200 mesh are available. There will be different sizes on display, including an RSFgenius 330, which will be the biggest filter on the Gneuss booth this year. It offers an active filtration area of 2150 cm2 and will be shipped to an end customer in Southern Europe after the show.

Last but by no means least, Gneuss will exhibit two KF screen changers, a KF 75 with an active screen area of 44 cm2 and a KF 110 with an active screen area of 95 cm2 .

The KF 110 will be installed in a blown film line at Brazilian machinery manufacturer Carnevalli’s booth (hall 16, stand C70). The KF series of continuous filtration systems is designed specifically for applications with frequent material type, grade or color changes as well as for high pressure applications like blown film.

Gneuss also offers a new semi-continuous model, the CSFprimus. This model is used as a pre-filer, safety filter or in applications with little contamination and is characterized by a very large active screen area for its small footprint.


Second generation MRS extruder with further improved IV retention and enhanced drive design

Gneuss Extrusion Technology will show a complete Gneuss Processing Unit (GPU) including a second generation Multi Rotation System MRS110 extruder, a fully automatic melt filtration system RSFgenius 90 and a new style online viscometer VIS, for the processing of 600 kg/h of undried and uncrystallized polyester (PET).

The Gneuss Processing Unit (GPU) has been available for more than a decade now and has proven itself for the reprocessing of highly contaminated materials without pre-drying, especially bulky PET waste such as post-consumer bottle flakes and industrial waste from fiber and film manufacture as well as polystyrene, nylon and other hydrophil polymers. A Gneuss Processing Unit consists of a Gneuss MRS extruder with its unmatched devolatilization and decontamination performance in combination with a highly-efficient Gneuss Rotary Filtration System and an online viscometer VIS for intelligent dynamic viscosity control.

The MRS extruder itself has been improved considerably over the last decade and at the K show the second generation design will be on display. The enhanced drive design is more robust to handle even more demanding recycling environments. Thanks to several changes in the MRS drum and screw design the already unmatched IV retention has been further improved, while continuing to forgo pre-drying. The MRS extruder permits the processing of PET without pre-drying by using a simple water ring vacuum system to process the material directly to high quality end products such as packaging sheet, strapping tape or filaments. This is achieved by means of its unique and patented processing section. Based on a conventional single screw extruder, the Multi Rotation Section is a drum containing eight satellite single screws, driven by a ring gear and pinion transmission. The “barrels” cut into the drum are approximately 30 % open and provide optimum exposure of the melt.

Thanks to this design, the devolatilizing performance is approx. fifty (50!) times greater than that of a conventional vented single screw extruder – and this at a vacuum of only 25 to 40 mbar. While other dryerless technologies are promoting at least partial pre-drying in the meantime, the MRS extruder can process R-PET with up to 1 % moisture content. By avoiding the need for a deep vacuum system and pre-drying, the MRS is an economically efficient alternative to conventional technologies. Further arguments in its favor besides energy savings are the simple and rugged design, small footprint, its ease of operation and low maintenance, processing flexibility and last but not least its excellent melt quality and homogeneity. A Letter of Non Objection (LNO) from the FDA, EFSA conformity and several local approvals in Latin America confirm the decontamination efficiency of this technology.

One area this has been especially successful is in PET sheet extrusion. The line at the K will be delivered to a customer in Brazil after the show to process R-PET into a packaging sheet.

In parallel, with Gneuss’ headquarters only about 200 km from the show, a complete PET sheet extrusion line with a Gneuss GPU will be running in Gneuss’ technical center open to visitors.

Polyreactor JUMP

Additionally, the previously exhibited polyreactor JUMP will be operating in Gneuss’ technical center for an online demonstration. The JUMP can lift the IV value of a PET melt up to 0,95 dl/g.

The reactor is installed directly downstream of a Gneuss Processing Unit and the polymer passes over several slow turning elements which create a polymer film, the surface of which is constantly renewed. The reactor vessel is kept under vacuum, through which volatile substances are reliably removed. By regulating the residence time in the reactor, the vacuum, the fill level and the speed of rotation of the agitating devices, the polycondensation reaction can be altered to achieve the required product properties. The JUMP is a compact, quick and efficient alternative to conventional SSP (solid state) systems and enables direct reintroduction of the polymer into the production process without the need to remelt the PET.


IO-Link melt pressure sensors for digital communication

The days of analogue measurement value transmission in polymer technology are numbered. With the requirements for flexibility, availability and safety of the machines and systems becoming more and more stringent, there is a need for new, digital solutions.

IO-Link is a worldwide standardised technology for digital linking of sensors and actuators. Communication takes place over a point-to-point connection and is thus not a field bus. IO-Link is manufacturer-independent and is becoming more and more widespread in industrial automation engineering. Most renowned controller manufacturers offer IO-Link masters, which are either directly fitted as an assembly in the controller or installed in the field and connected via a bus system.

The traditional melt pressure sensor with an analogue output knows significantly more than just the process pressure. The signal preparation on its inside has been digitised long ago, and as a result, it is in a position to provide valuable information that simplifies maintenance, increases safety and improves availability. Preventive maintenance and condition monitoring can minimise downtimes and optimise process safety. The melt pressure sensor could make a substantial contribution in this regard, if it could divulge its knowledge. But unfortunately, its communications facilities are limited to one direction and one measurement value.

The Gneuss IO-Link sensor offers the possibility to access all those information. Its proven sensor technology, in combination with intelligent, digital communication not only offers monitoring of the electronics temperature, but also records the operating hours in different load ranges. Thus, the user can make out, during ongoing operation, when the electronics head is subject to high heat radiation due to its installation location, or the sensor is continuously working at the upper limit of its measurement range.

Advantages of Gneuss digital pressure sensors:

  • Monitoring of the electronics temperature
  • Recording of operating hours in different load ranges
  • Reporting of defined test intervalls
  • „Digitales type plates“ for definite assignment of the appropriate sensor for the special application
  • Increased flexibility, availability and safety of machines and systems

In addition, Gneuss' Measurement Technology division will present its complete line of pressure transducers and transmitters, temperature sensors and accessories.