Pure Loop, a member of the EREMA Group, is advancing automation on its Isec evo recycling machine with DynaShape, an adaptive control solution designed to match machine settings to changing feed material conditions. Developed to optimise parameters such as feed and intake in real time, DynaShape keeps throughput and melt quality stable even when the input stream fluctuates during production. In test runs simulating typical shifts in production waste, including variations in shape and bulk density, the company recorded productivity increases of up to ten percent. The Isec evo integrates a shredder and extruder with a patented double feed ram system and a conical transition to the extruder, enabling processing of clumps, guillotined film rolls, film shreds, glass fibre reinforced plastics and fibres into recycled pellets. Historically, achieving maximum performance often required an experienced technician to fine tune parameters. With DynaShape, those adjustments are automated so the machine can operate consistently at its potential across applications, reducing operator workload and time to optimal output. According to Pure Loop, the automation particularly benefits demanding streams such as injection moulding waste, where shapes range from start up lumps to sprues and regrind, and PVC pipe production waste, which can vary from large pipe sections to fine shavings.
Intelligent automation maintains a stable process
The company positions DynaShape as a tool that replicates expert level parameter optimisation. “DynaShape regulates our recycling machine to get the perfect settings. It does it as precisely as a professional technician with ten years of experience,” said Manfred Dobersberger, Managing Director of Pure Loop. “Our customers get the advantage of higher throughputs with consistent high quality and a noticeable reduction in operator workload. The technology is in a class of its own when processing challenging applications with fluctuations in feed material shapes and bulk densities; tasks for which the Isec evo is predestined.”
Over the past decade, the Isec evo has been used to process diverse production scrap into recycled pellets. With DynaShape, the machine responds automatically to shifts in feed characteristics so operators do not have to intervene to maintain throughput or quality. The system also allows saving the optimised settings as a recipe, so subsequent start ups can immediately run with the stored parameters, further reducing manual adjustments.
Dynamic interaction of feed rams and intake apertures
The core of DynaShape is the coordinated control of two elements in the shredder extruder interface. The double feed ram system now adjusts its speed dynamically in line with rotor load, while the hydraulically adjustable intake apertures switch from manual to automatic regulation. This interaction is intended to raise throughput and improve melt quality. With consistent melt pressure and an optimised extruder screw filling level, the system avoids oxidative degradation of the melt. In addition, operators can set a maximum melt temperature for each polymer. Unlike manual operation, DynaShape reacts immediately to temperature increases to keep the specified limit from being exceeded.
Additional updates: EcoGentle and wear monitoring
At K 2025, Pure Loop is also introducing further Isec evo options. EcoGentle plasticising technology, developed by sister company Erema, is now available for polyolefins and has been adapted jointly for the Isec evo to reduce energy consumption by lowering melt temperature. The firm is presenting an intelligent assistance system, PredictOn:Plastification Unit, originally developed by EREMA to monitor wear of the extruder screw and barrel. Pure Loop extends the monitoring to include the conical intake zone between the shredder and extruder. The company states that this significantly increases machine uptime. The benefit is particularly relevant when processing abrasive materials, such as injection moulded parts containing glass fibres, helping to avoid unexpected downtime.
Pure Loop plans to make the DynaShape automation solution available for Isec evo starting October 2025. Visitors can find the company at K 2025, Hall 9, Stand C09.
Manfred Dobersberger, Managing Director of Pure Loop, presents DynaShape, the intelligent automation solution for the Isec evo recycling machine at the K trade fair in Düsseldorf.
