7/30/24

voestalpine HPM solutions for melt filtration of 1st generation and recycled plastics

In this article we briefly discuss the increased use of recycled plastic in injection molding as part of the solution for a carbon-neutral circular economy. We also show how voestalpine High Performance Metals (HPM) has developed filter solutions to remove contaminants in the plastic melt, allow the mixing of plastic materials, and minimize machine pressure drop associated with filtration.

THE PLASTICS TRANSITION ROADMAP FOR SUSTAINABLE PLASTICS

The Plastics Transition roadmap published by Plastics Europe clearly sets out the change required to make the transition to a carbon-neutral circular economy by 2050. The reuse of plastics— including mechanical and chemical recycled plastics, as well as plastics from biomass—is a vital element for sustainable plastics. And it is here that we take a closer look at the implications of using such recycled material in the plastic injection molding process.

FILTRATION OF CONTAMINANTS IN RECYCLED PLASTIC MELT

Although all plastic pellets could contain some contaminants, for recycled plastics the possibility and number of contaminations are at a significantly higher level. This is due to the broader range of sources. Even with continuous improvements in the collection and sorting process, post-consumer plastics such as PET flakes or pellets require careful filtration to remove contaminants when used for injection molding.

The diagram below illustrates the circular economy for the mechanical recycling of plastics:

Diagram: Mechanical recycling is one of the most common methods for recycling plastic.

CONTAMINANTS ARISING FROM MECHANICAL RECYCLING

Along with the various substances formed during production of 1^st generation plastic, the mechanical recycling of plastic material introduces further substances and contaminants through previous use, waste collection, and the recycling process itself.

When using these recycled products, injection molders must ensure that they use the right melt filtration system that can remove the contaminants in the plastic stream and still achieve a reliable and stable operation with minimal maintenance requirements. Often though, additional filtration systems or components cause a large pressure drop that has a negative impact on the injection process. This is where voestalpine Flow Filter V & X offer a superior solution:

VOESTALPINE FLOW FILTER V & X OFFER SUPERIOR PERFORMANCE

As part of the voestalpine Engineered Products range for Plastic Injection Molding, voestalpine Flow Filter V & X capitalize on the unique capabilities of additive manufacturing to create a high-density solid mesh filter. These filter solutions solve the main industrial problem of large pressure-drop loss on machines caused by the use of conventional filtration systems.

Depending on operational requirements, customers can choose from two filter solutions:

voestalpine Flow Filter V for minimal pressure drop.
voestalpine Flow Filer X with additional mixing element.

VOESTALPINE FLOW FILTER V	VOESTALPINE FLOW FILTER X

Flow Filter V prevents contamination of the plastic melt at a significantly lowered pressure drop (up to 65% compared to standard industry comb filters). These filters are ideal for high-density and sensitive plastics, as well as recycled plastics.	Flow Filter X prevents contamination of the plastic melt and can mix two plastics with good fluidity.
FLOW FILTER V ADVANTAGES minimized pressure drop very large filtration area minimal shear stress same high filter quality with small mesh size for all filter diameters easy cleaning and trouble-free color changes long lifetime, high wear and corrosion resistance improved part quality	FLOW FILTER X ADVANTAGES combined filter and mixer in one single component even distribution of color particles reduced masterbatch consumption (cost savings) same high filter quality with small mesh size for all filter diameters easy cleaning and trouble-free color changes long lifetime, high wear and corrosion resistance improved part quality

VOESTALPINE FLOW FILTER V

VOESTALPINE FLOW FILTER X

voestalpine Flow Filter V

Flow Filter V prevents contamination of the plastic melt at a significantly lowered pressure drop (up to 65% compared to standard industry comb filters). These filters are ideal for high-density and sensitive plastics, as well as recycled plastics.

Flow Filter X prevents contamination of the plastic melt and can mix two plastics with good fluidity.

FLOW FILTER V ADVANTAGES

minimized pressure drop
very large filtration area
minimal shear stress
same high filter quality with small mesh size for all filter diameters
easy cleaning and trouble-free color changes
long lifetime, high wear and corrosion resistance
improved part quality

FLOW FILTER X ADVANTAGES

combined filter and mixer in one single component
even distribution of color particles
reduced masterbatch consumption (cost savings)
same high filter quality with small mesh size for all filter diameters
easy cleaning and trouble-free color changes
long lifetime, high wear and corrosion resistance
improved part quality

DIMENSIONS

voestalpine Flow Filter V & X come in standard industry and customized dimensions:

VOESTALPINE EXPERTS ARE READY TO HELP YOU

By using voestalpine Flow Filter V & X in your injection molding machines, your operation can effectively use 1^st generation or recycled plastic pellets and benefit from the many advantages discussed in this article. These filter solutions are part of the voestalpine range of Engineered Products for Plastic Injection Molding. You can find out about the full range here.

Our experts are also ready to help discuss your unique injection molding needs. You can contact them using the button below:

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