MAS and Siempelkamp Size Reduction, formerly Pallmann, have combined their process know-how to develop a next-generation solution for demanding film recycling applications: the iQonicTwin PreDensifier. Post-consumer film recycling is gaining importance in packaging, yet handling lightweight, fluffy films with air pockets, inks and adhesive layers remains difficult. Such feedstocks tend to cause quality fluctuations and energy inefficiencies during processing. While a conventional cutter compactor route was evaluated, the partners targeted higher process stability and consistent output quality. As they state, "The iQonicTwin PreDensifier represents the fusion of two proven top technologies and marks a significant leap forward in recycling process stability, efficiency, and product quality." The concept integrates Pallmann's high-performance PreDensifier with MAS's energy-efficient conical co-rotating twin-screw extruder. According to the companies, cutter compactors can no longer meet growing demands for top quality because their process control does not ensure a uniform melting process, which leads to fluctuations in extruder feed.
Key features and performance
The iQonicTwin PreDensifier is designed to stabilize, automate and simplify the transition from low-bulk-density inputs to a uniform extruder feed. The partners highlight the following attributes:
- Significantly reduced gel formation and black spots, due to low energy input and less mechanical stress
- Stable, reliable and reproducible processing, even with fluctuating feedstocks, resulting in consistent material quality
- High energy efficiency, approximately 0.15 kWh/kg
- No dust emission and no water injection
- Compact design and simplified maintenance, enabling seamless integration into existing systems
- Instant start and stop capability, no warm-up needed
- Easy cleaning for faster material change
- Full process control, including start and stop, emergency stop and monitoring
- No cake formation typical of cutter compactors
- High level of automation
Applications and launch
The system addresses a wide range of feedstocks including: post-consumer films, fibers, PP ropes, nonwoven materials, fleece and XPS. In these applications it aims to deliver a uniform, high-quality feed to the extruder while minimizing thermal and mechanical stress on the material.
The iQonicTwin PreDensifier is available and will be officially introduced at the K show in Düsseldorf from October 8 to 15 at booth MAS@D30 and Pallmann@A10.
