Extrusion International 5-2025-USA

78 Extrusion International 5/2025 RECYCLING important to consider the entire pro- cess chain. In particular, howmaterial losses and rejection quantities during the recycling process impact the nal output. A jointly developed model by Lindner Washtech and EREMA makes it possible to precisely design a plant according to the required to- tal throughput, taking into account the speci c output and materials from the raw material to the nal re - cyclate. Intelligent energy ef ciency The ef cient use of spent energy is one of many challenges in the re- cycling process – and it particularly affects the transition from drying to extrusion. This is precisely where a common control concept between the bunker silo and extruder comes into play. Dynamic system synchro- nisation allows operators to speci - cally control the dwell time of the dried material as well as the extruder loading. For example, the automatic signal exchange ensures that the pre- conditioning unit (PCU) receives an optimum quantity of akes at the ideal temperature, which signi cant - ly reduces the energy required for heating, for example. Smooth and automated material ow regulation Low downtimes are vital in matters of productivity and energy use to con- serve resources. It is all the more im- portant for all interruptions to the ma- terial ow to be identi ed as early as possible. The solution: a combined con- trol concept. If the recycling process is interrupted by scheduled maintenance work, lter changes or the need to remove contaminants from the shred- der, the system will automatically de- tect this. Intelligent control parameters will keep the recycling process stable until maintenance is complete or the fault has been solved. This effectively prevents energy losses, unnecessary material waste and unplanned down- time. Once the material ow has been fully restored, the line automatically and seamlessly ramps up – ensuring a consistent and high-quality granulate production at all times. Smart performance monitoring Lindner Washtech and EREMA have added another jointly developed fea- ture to analyse and monitor overall performance: a process-oriented HMI dashboard that displays all the criti- cal plant parameters in real time. This adaptive interface supplies operating personnel with information about the current utilisation, likely bottlenecks and the potential for optimisation. Operators can then use this informa- tion to respond to the speci c issue – and monitor the automatic interven- tion. The integrated transparency supports a stable, data-driven plant operation, forming the basis for fu- ture automated interventions and condition-based maintenance (CBM). The development of integrated, da- ta-driven and holistic process solutions are key milestones in the strategic col- laboration of Lindner Washtech and EREMA. A strong shared foundation has been created with the founda- tion of this joint venture. At K 2025 in Düsseldorf, the partners will focus on key themes such as integrated plant concepts, smooth material ow regu - lation, smart monitoring and data- driven, intelligent control systems – for maximum process control and optimi- sation along the entire value-added chain and for new process and quality standards in plastics recycling: Innovat- ing the standards in plastics recycling. Lindner Washtech GmbH www.lindner.com Establishing the Tray-to-Tray Recycling Market – Technology, Scale and Challenges T ray-to-tray recycling is becoming a recognized ap- proach for advancing circularity in plastic packaging – especially for food-grade applications. Valerio Sama, Business Development Manager – Packaging at TOMRA Recycling, examines the latest developments in tray-to- tray recycling, detailing the challenges, technologies and market trends shaping its growth across the industry. Unlike bottle-to-bottle recycling, the PET tray stream has historically been underutilized; trays were rarely collected or recycled prior to the early 2020s. When re- cycled content was used in trays, it typically came from bottles, raising concerns about diverting valuable feed- stock away from closed-loop bottle systems. This histori- cal oversight has led to a signi cant environmental bur - den: while approximately 1 million tons of PET trays are introduced to the European Union market each year, a staggering 70% of this valuable material is lost, with only around 300,000 tons currently collected for recy- cling. This represents a critical missed opportunity for circularity and highlights the urgent need for improved collection and recycling infrastructure. Fortunately, tray-to-tray recycling has recently gained traction as an emerging solution within the broader ef- fort to improve plastic packaging circularity. This shift is largely driven by recent changes in EU legislation, in- cluding the Single-Use Plastics Directive (SUPD) and the